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How to achieve high precision with an injection molding machine?

2024/06/21 By Topstar

plastic-bottle making machine

Companies that manufacture high-precision plastic products are often more favored by users, and the high precision of parts is also a standard for judging a manufacturing company and the equipment they use. So for injection molding, how can the injection molding machine achieve high precision to produce high-quality parts? In this guide, we will share several aspects so that you can understand systematically how to achieve high accuracy.

Choose the right injection molding machine

If you want to achieve high precision in injection molding, the first step is choosing a suitable injection molding machine. Because the control and drive systems of different types of machines are different, the various factors in them will affect the precision capabilities of the machine.

Machine type: Different injection molding machines, such as hydraulic, electric, and hybrid, can provide different degrees of precision.

Electric machines:

They use servo motors for all significant injection, clamping, ejection, and other movements and can accurately control speed, pressure, and position. Electric machines have the characteristics of accuracy, repeatability, and high energy efficiency.

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Hydraulic press:

Traditional hydraulic presses are not as accurate as electric machines, but hydraulic presses using related technologies can also improve precision to a certain extent. In comparison, it is more cost-effective and suitable for more significant parts that require high strength.

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Hybrid machines:

Hybrid machines combine the best of both worlds, using electric drives for precision control and hydraulic systems for high-intensity control, making them versatile and capable of achieving high precision in various applications.

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Optimize molding parameters for precision

After selecting the suitable injection molding machine, optimizing molding parameters during the injection molding process is necessary to achieve higher precision. Key parameters that must be carefully controlled include temperature, pressure, speed, etc.

Temperature control: Precise control of melt and mold temperature is essential to ensure consistent material flow and avoid defects such as dents and warping while ensuring the regular operation of the heating and cooling systems. This can be achieved by using different mould temperature controllers.

Injection pressure and speed: On the one hand, the intelligent electric injection motion can control time, pressure, position PV, and speed conversion to accurately balance thoroughly filling the mold and avoiding excessive pressure on the material. On the other hand, the automatic compensation function of the manipulator mold opening position can achieve accurate grasping and placement of the manipulator.

Back pressure: Applying the correct back pressure during the plasticization stage helps achieve uniform melt density and avoid problems such as air entrapment and material degradation. You can adjust the back pressure according to the material properties and the specific requirements of the molded part.

Select high-quality injection molding materials

Select high-quality injection molding materials

The material selection in the injection molding process also has a certain degree of influence on the precision and quality of the parts. High-quality materials often ensure the product’s consistent performance.

Material properties: We need to consider the mechanical, thermal, and chemical properties of the materials used for injection molding. Factors such as melt flow index, shrinkage, and thermal conductivity will affect the molding process and the quality of the final part. Materials compatible with the required application and performance requirements need to be used.

Material Handling: Ensure materials are stored in a controlled environment to prevent contamination and moisture absorption. Drying equipment is required to remove moisture from hygroscopic materials before processing.

Ensure mold quality and maintenance

The quality and maintenance of the mold also help the injection molding machine achieve high precision. Well-designed and adequately maintained molds ensure consistent part quality and minimize the risk of defects.

Mold design: Factors such as gate location, venting, cooling channels, and ejection systems should be considered when designing the mold. Proper gate design ensures uniform material flow and reduces the risk of flow marks and weld lines. Adequate venting prevents cavitation and burns, while effective cooling channels ensure uniform cooling and shorten cycle times.

Maintenance practices: Regular maintenance of molds is essential to prevent wear, avoid production downtime, and maintain high precision. This includes cleaning mold surfaces, checking for wear and damage, and ensuring that cooling channels and ventilation systems function correctly.

Getting high-precision injection molding

You need a comprehensive approach to achieve high precision in injection molding machines. As mentioned in the article, selecting a suitable machine, optimizing molding parameters, ensuring mold quality, etc., are critical to ensuring the molded parts’ dimensional accuracy, consistency, and overall quality. Only by doing these details well can you get high-precision parts.

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