//Plastic Injection Molding
  • plastic injection molding
  • plastic injection molding
  • plastic injetion molding
  • plastic injetion molding

Plastic Injection Molding

Approximately 30% of all plastic products are produced using an plastic injection molding process. Of this 30%, a large amount of these products are produced by using custom plastic injection molding technology. Six steps are involved in the plastic injection molding process, after the prototype has been made and approved.
The first step to the injection molding process is the clamping of the mold. While the melted plastic is being injected and cooled.
Next is the actual injection of the melted plastic. The plastic stays in the mold, where it is being clamped under pressure until it cools.
The next couple of steps consist of the dwelling phase, which is basically making sure that all of the cavities of the mold are filled with the melted plastic. After the dwelling phase, the cooling process begins and continues until the plastic becomes solid inside the form. Finally, the mold is opened and the newly formed plastic part is ejected from its mold. The part is cleaned of any extra plastic from the mold.

Product Description

There are many types of materials that may be used in the plastic injection molding process. Most polymers may be used, including all thermoplastics, some thermosets, and some elastomers. When these materials are used in the plastic injection molding process, their raw form is usually small pellets or a fine powder. Also, colorants may be added in the process to control the color of the final part. The selection of a material for creating injection molded parts is not solely based upon the desired characteristics of the final part. While each material has different properties that will affect the strength and function of the final part, these properties also dictate the parameters used in processing these materials. Each material requires a different set of processing parameters in the plastic injection molding process, including the injection temperature, injection pressure, mold temperature, ejection temperature, and cycle time. A comparison of some commonly used materials is shown below.

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Material name Abbr. Trade names Description Applications
Acetal POM Celcon, Delrin, Hostaform, Lucel Strong, rigid, excellent fatigue resistance, excellent creep resistance, chemical resistance, moisture resistance, naturally opaque white, low/medium cost Bearings, cams, gears, handles, plumbing components, rollers, rotors, slide guides, valves
Acrylic PMMA Diakon, Oroglas, Lucite, Plexiglas Rigid, brittle, scratch resistant, transparent, optical clarity, low/medium cost Display stands, knobs, lenses, light housings, panels, reflectors, signs, shelves, trays
Acrylonitrile Butadiene Styrene ABS Cycolac, Magnum, Novodur, Terluran Strong, flexible, low mold shrinkage (tight tolerances), chemical resistance, electroplating capability, naturally opaque, low/medium cost Automotive (consoles, panels, trim, vents), boxes, gauges, housings, inhalors, toys
Cellulose Acetate CA Dexel, Cellidor, Setilithe Tough, transparent, high cost Handles, eyeglass frames
Polyamide 6 (Nylon) PA6 Akulon, Ultramid, Grilon High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque/white, medium/high cost Bearings, bushings, gears, rollers, wheels
Polyamide 6/6 (Nylon) PA6/6 Kopa, Zytel, Radilon High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque/white, medium/high cost Handles, levers, small housings, zip ties
Polyamide 11+12 (Nylon) PA11+12 Rilsan, Grilamid High strength, fatigue resistance, chemical resistance, low creep, low friction, almost opaque to clear, very high cost Air filters, eyeglass frames, safety masks
Polycarbonate PC Calibre, Lexan, Makrolon Very tough, temperature resistance, dimensional stability, transparent, high cost Automotive (panels, lenses, consoles), bottles, containers, housings, light covers, reflectors, safety helmets and shields
Polyester – Thermoplastic PBT, PET Celanex, Crastin, Lupox, Rynite, Valox Rigid, heat resistance, chemical resistance, medium/high cost Automotive (filters, handles, pumps), bearings, cams, electrical components (connectors, sensors), gears, housings, rollers, switches, valves
Polyether Sulphone PES Victrex, Udel Tough, very high chemical resistance, clear, very high cost Valves
Polyetheretherketone PEEKEEK Strong, thermal stability, chemical resistance, abrasion resistance, low moisture absorption Aircraft components, electrical connectors, pump impellers, seals
Polyetherimide PEI Ultem Heat resistance, flame resistance, transparent (amber color) Electrical components (connectors, boards, switches), covers, sheilds, surgical tools
Polyethylene – Low Density LDPE Alkathene, Escorene, Novex Lightweight, tough and flexible, excellent chemical resistance, natural waxy appearance, low cost Kitchenware, housings, covers, and containers
Polyethylene – High Density HDPE Eraclene, Hostalen, Stamylan Tough and stiff, excellent chemical resistance, natural waxy appearance, low cost Chair seats, housings, covers, and containers
Polyphenylene Oxide PPO Noryl, Thermocomp, Vamporan Tough, heat resistance, flame resistance, dimensional stability, low water absorption, electroplating capability, high cost Automotive (housings, panels), electrical components, housings, plumbing components
Polyphenylene Sulphide PPS Ryton, Fortron Very high strength, heat resistance, brown, very high cost Bearings, covers, fuel system components, guides, switches, and shields
Polypropylene PP Novolen, Appryl, Escorene Lightweight, heat resistance, high chemical resistance, scratch resistance, natural waxy appearance, tough and stiff, low cost. Automotive (bumpers, covers, trim), bottles, caps, crates, handles, housings
Polystyrene – General purpose GPPS Lacqrene, Styron, Solarene Brittle, transparent, low cost Cosmetics packaging, pens
Polystyrene – High impact HIPS Polystyrol, Kostil, Polystar Impact strength, rigidity, toughness, dimensional stability, naturally translucent, low cost Electronic housings, food containers, toys
Polyvinyl Chloride – Plasticised PVC Welvic, Varlan Tough, flexible, flame resistance, transparent or opaque, low cost Electrical insulation, housewares, medical tubing, shoe soles, toys
Polyvinyl Chloride – Rigid UPVC Polycol, Trosiplast Tough, flexible, flame resistance, transparent or opaque, low cost Outdoor applications (drains, fittings, gutters)
Styrene Acrylonitrile SAN Luran, Arpylene, Starex Stiff, brittle, chemical resistance, heat resistance, hydrolytically stable, transparent, low cost Housewares, knobs, syringes
Thermoplastic Elastomer/Rubber TPE/R Hytrel, Santoprene, Sarlink Tough, flexible, high cost Bushings, electrical components, seals, washers

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