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What size injection molding machine do l need?

2024/03/18 By Topstar

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Injection molding machines can be divided into large and small-size injection molding machines according to size. These two sizes are suitable for injection molding of different products, and their injection molding processes are also different. Therefore, the right size is crucial to obtain the product during manufacturing. Whether you produce small or large components, choosing the right machine size can significantly impact efficiency and quality. In this guide, we take you through the factors to consider when sizing your injection molding machine based on your needs.

Features of Large Size Injection Molding Machine

Large-size injection molding machines are equipment specifically used to produce large plastic parts in the manufacturing industry and are suitable for handling large-scale injection molding projects. Large-size injection molding machines are equipped with high-tonnage (generally 2200T) mold clamping devices, which can exert a large force to keep the mold closed during the injection process. This allows them to fit into large, heavy molds required to produce large plastic parts. These machines also feature wide platens or mold mounting surfaces, ensuring stable and even clamping force distribution across the entire mold. They can accommodate large molds and provide ample space for producing large parts.

Meanwhile, large-size injection molding machines efficiently fill large molds with molten plastic. These machines are equipped with high-capacity injection devices capable of delivering large amounts of material under high pressure. Structurally, they can withstand the intense forces and pressures generated when molding large parts, ensuring durability, stability, and reliable performance over long periods of operation.

Large Size Injection Molding Machine

Features of small-size injection molding machines

Small-size injection molding machines are also ubiquitous in the manufacturing industry. They are mainly multi-functional tools for producing small and medium-sized plastic parts and assemblies. Their small footprint makes them suitable for small workshops with limited space. These machines typically have lower clamping forces (generally between 90T-470T) than their larger counterparts, making them ideal for molding small, delicate parts at lower injection pressures.

The injection device of a small injection molding machine provides a small injection volume of molten plastic material. This allows precise control of the amount of material injected into the mold cavity, ensuring the molding of small plastic products. Manufacturers optimize them for fast cycle times, enabling them to produce small parts at high speeds with short cooling and ejection times. This increases productivity and throughput.

small-size injection molding machines

What different products are suitable for production?

Large and small injection molding machines are suitable for producing different types of products based on their respective characteristics and capabilities. Large-size injection molding is often used to make automotive parts such as bumpers, instrument panels, and interior trim panels. It can also produce plastic casing parts commonly required for large household appliances such as refrigerators, washing machines, and dishwashers and large plastic parts used in furniture, such as chair frames, table legs, and cabinet panels.

Washing machine plastic casing

Small injection molding machines are very suitable for producing small plastic parts. This includes connectors, housings, brackets, and switches for consumer electronics, computers, and telecommunications equipment. Also included are those used in the production of medical devices and equipment. Includes syringe barrels, surgical instrument handles, medical tubing, and small plastic parts used in consumer products such as toys, sporting goods, household goods, and packaging.

plastic toys

Energy Efficiency of Large and Small Injection Molding Machines

Energy efficiency is a crucial difference between large and small-size injection molding machines. Large-size injection molding machines often use hydraulic systems with variable frequency drives (VFD) and servo motors. These systems adjust pump speed and motor output based on actual demand, reducing Energy consumption during idle and low-load periods. Some large-size injection molding machines also have energy recovery systems that capture and reuse hydraulic energy during the deceleration phase of machine operation. The system stores and reuses the recovered energy to power other machine functions, reducing energy consumption.

Small-size injection molding machines usually use all-electric drive systems, eliminating the need for hydraulic systems and reducing energy consumption. Electric servo motors precisely control machine functions, minimizing energy losses and optimizing efficiency. They also use an efficient electric heating system to melt the plastic material and inject it into the mold, allowing precise temperature control and rapid heating capabilities to reduce energy consumption and cycle times.

Differences in life cycle maintenance costs

The life cycle maintenance costs of large and small-size injection molding machines vary significantly due to differences in machine complexity, operating conditions, and maintenance requirements. Large-size injection molding machines typically require higher upfront investments due to their larger size, higher clamping forces, and more complex hydraulic or hybrid drive systems. They have complex mechanical and electrical components that require regular inspection and lubrication to ensure optimal performance. Over time, larger machines’ more prominent size and higher operating pressures can lead to more significant wear and tear on machine components. This can result in more frequent replacement of worn parts such as screws, barrels, and seals and thus increased maintenance costs.

Small-format injection molding machines typically have lower upfront costs due to their smaller dimensions, lower clamping forces, and simpler electric drive systems. This makes them more accessible to small businesses and startups with limited capital budgets. They have fewer mechanical and hydraulic components, simplifying maintenance procedures and reducing labor requirements. Routine maintenance tasks such as cleaning, lubricating, and replacing parts may be more manageable, reducing wear and tear.

Choose according to your situation

Large-size injection molding machines are your first choice for manufacturers who want to produce auto parts, large household appliances, and large plastic parts. Small-size injection molding machines are your best choice for manufacturers of small plastic parts, medical devices, and small plastic parts for household products.

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