Tooling Investment Costs. When a electric car mould part is being manufactured for the first time, the design is first prototyped with a test material to ensure accuracy using techniques such as 3D printing or CNC machining. The mold tool is made of steel or aluminum material and must be designed to precise dimensions.
Mold Temperature. The temperature of the precision mold is another essential consideration that affects the quality of the injection-molded part. Getting the best quality mold is a balance between heating the mixture sufficiently to create a homogeneous mixture and cooling it down at an ideal rate. Anything else would be undercooling or overcooling.
Undercooling and Overcooling Issues. Improper polymer flow is a direct consequence of under- or overcooling issues in plastic injection mould. When the mixture is not cooled sufficiently, it may not solidify completely before being ejected. This may leave residual plastic in the mold.
Plastic moulding is the process of pouring liquid plastic into a certain container or mould so that it hardens in that customized shape. These plastic moulds can then be used for a wide range of purposed. There are 5 types of plastic moulding that is considered to be the most effective and most popular.
These 5 types are extrusion moulding, compression moulding, blow moulding, injection moulding and rotational moulding. We will look at the details pertaining to each of these methods so that you can decide which one will be the most effective for you to use.
1. Extrusion Moulding
With extrusion moulding, hot melted plastic is pressed through a shaped hole to create a lengthy shaped plastic part. This customizable shape that the liquid plastic gets pressed through is called a die. This die is custom made for the particular outcome that is desired. It is almost like pressing dough through a press to make shaped cookies.
The other forms of plastic moulding also use extrusion so get the raw liquid into the commodity mould, the difference here is that other methods use the moulds to make the desired shape and here the extrusion itself is making the shape with the use of the die’s shape.
The sensing of the injection molding process is focused on the temperature, pressure, position, speed, etc., which reflect the physical state of the process. Temperature and pressure are the two fundamental physical variables that are the most important in the injection molding process. Furthermore, among various sensing technologies, temperature and pressure sensors are the most well developed and the most widely utilized. By means of sensing the temperature and pressure, one can obtain abundant information about the mold and polymer melt. With continuing technology development, some new methods have emerged in the field of injection molding. Some of them are capable of characterizing more variables besides temperature, pressure, position, and speed. This section will briefly introduce the conventional and emerging methods used in injection molding processes and the up-to-date research progress. Finally, a conclusion and analysis will be put forward and discussed.