If you’re looking to have precise and/or identical components created for a project and looking for the best way to have this done, you may have come across plastic injection moulding. If you’ve not heard of or used this process before however you may be a bit confused as to what it is exactly and how it benefits precision manufacturing. Here’s our guide on what plastic injection moulding is and the main aspects of this process you should know about!
What Is Plastic Injection Moulding?
Plastic injection moulding is a manufacturing process that is used to produce extremely precise and identical components in high volumes by injecting a molten synthetic polymer material into a metal mold where it then cools down and solidifies. When a project needs multiple complicated shapes being produced very consistently and at an affordable per-component price, this is the process that can make that possible. You may also come across the process being referred to as ‘high-volume plastic manufacturing’ and/or ‘polymer processing.’
Plastic Injection Moulding Applications
Plastic injection moulding has a vast array of applications across multiple industries and products manufactured using this process can be found absolutely anywhere from your home to industrial spaces. It’s used for everything from automotive components to medical tools and everyday use objects like cutlery. If you’re interested to learn more about these applications, we have a dedicated blog on what plastic injection moulding is used for which you can take a look at.
How Does Plastic Injection Moulding Work?
Plastic injection moulding works by injecting molten polymers extremely quickly (often in the span of 0.1 to a few seconds) into a mould cavity. This mould is specifically machined beforehand to provide the component results you’re looking for, e.g. polished/textured or any other type of finish you need. Once this is all in place, manufacturing follows a repeatable cycle:
- The two mould halves are clamped together under high pressure
- Molten polymer material is injected into the mould cavity through a small nozzle
- The material cools down and solidifies inside the mould
- Ejector pins push the finished component out of the mould
What Plastics Are Used for Injection Moulding?
Many different types of polymers can be used for injection moulded components depending on what the requirements are for the finished part in terms of performance, intended environment, etc. Some of the most popular ones are:
- ABS
- Nylon (PA)
- Polycarbonate (PC)
- Polyoxymethylene (POM)
- Polyphenylene Oxide (PPO)
- PC+ABS
- Cycoloy
We do have a blog specifically on the plastics most commonly used in injection moulding so if you’d like to learn more about this, feel free to have a look.
How Long Does Injection Moulding Take?
Depending on the complexity of the part needing to be produced, the process can take anywhere from 4-10 weeks (tooling/mould machining process included) with simpler moulds taking about 3-4 weeks and more complex ones taking up to 10. The actual production cycle itself is incredibly fast, typically 10 to 60 seconds per cycle.
Advantages of Plastic Injection Moulding
There are multiple benefits to this process depending on what your product is and the intended use of the part you’re looking to have manufactured. Here are some of the main advantages relevant across almost any project:
- Cost per part significantly drops with high-volume production allowing you to cost effectively have precise identical parts manufactured
- Cycle times are extremely fast which means that once your mould is designed high volumes of components can be produced in a very short span of time
- The parts produced are completely identical and extremely precise even if shapes are complex
- Various polymers can be used to support different colour and performance requirements and fit the needs of your project
- The process generates a very low amount of waste and any excess material can be recycled
To learn more about these benefits, take a look at our blog explaining why businesses use injection moulding and the factors to consider.
Why Is Injection Moulding Good for Precision Manufacturing?
When it comes to precision manufacturing, injection moulding is an absolute cornerstone of any production process simply because it allows you to have automated production of very intricate, very precise components with extreme consistency and excellent repeatability. It can support tolerances as tight as 0.01mm and less across high volume production runs.
How to Choose a Plastic Injection Moulding Company for Your Project
To choose the best company for your project, consider the services and capabilities you consider important. Are quick turnaround times something you prioritise? Are you looking to have a highly technical/complex part manufactured? If so, you might want to consider a provider with a good amount of experience in the field and high-tech equipment. You may also want to consider whether the supplier offers reshoring support in case you’ll be bringing manufacturing back to the UK from overseas. For projects that require extremely accurate components it’s also very important to choose a manufacturer who’s able to and experienced in working to very tight tolerances and precise specifications.
If there are any other services you’ll be needing as part of the process like laser etching (e.g. for medical components) or any specific finishes, you’ll need to make sure the provider offers these before committing. If you’re looking for more advice on choosing the best provider for your project, have a look at our guide on things to consider when choosing a plastic injection moulding supplier.
Fern Plastics has decades of experience in this industry and we’ve helped countless of clients bring their projects to reality. We offer a complete portfolio of services as well as fast turnaround times and competitive pricing and can help whether you’re looking to have new moulds created, repairs, maintenance or reshoring support. Get in touch with our team today to learn more about our services.