Chap 1 - Injection Moulding

INJECTION MOULDING
What Is Injection Moulding?

 Injection moulding is a manufacturing
process for producing parts by injecting
material into a mould. Injection can
moulding
be performed with a host of materials mainly
including metals, glasses, elastomers,
confections, and most commonly thermoplast
ic and thermosetting polymers. Material for the
part is fed into a heated barrel, mixed, and
forced into a mould cavity, where it cools and
hardens to the configuration of the cavity.
Injection Moulding Machine
Main Components Of Injection
Moulding Machine
 Clamping unit
 Injection unit
 Drive unit
 Mould
 Hydraulic system
 Control system
 Hopper
 Heaters
 Cooling channels
Injection Moulding Process -
Resources
 Material
 Machine
 Mould
 Manpower
Most Commonly Used Materials
 PVC
 ABS(Acrylonitrile Butadiene Styrene)
 Polypropylene
 Polystyrene
 HDPE( High density poly ethylene)
 LDPE(Low density poly ethylene)
 Rubber Thermoplastic
 Epoxy
Injection Moulding Process
 Material preparation
 Feeding into hopper
 Injection
 Mould holding and cooling
 Ejection
Process
 Material granules are fed into hopper then
melted down in barrel which is by
surrounded the heaters.
Process
 Melted material is injected into mould cavity
and mold is held under pressure until the
material cools and hardens.
Process
 Once the material hardens, the mold is opened
and the component is ejected by runner plate.
Process
 And the process can be repeated.
Process
Mould
 Moulds are the common terms used to describe
the tool used to produce components in moulding.
 Moulds are constructed from hardened steel, pre-
hardened steel, aluminium, beryllium-copper allo

y.
In general, steel moulds cost more to construct,
but their longer lifespan will offset the higher initial
cost over a higher number of parts made before

wearing out.
The moulds can be manufactured either by CNC
machining or by using electrical discharge
machining processes.
Mould Design
 The mould consists of two primary
components, the injection mould (A plate)
and the ejector mould (B plate).
Mould Design Consideration
 Shrinkage allowance: Depends on shrinkage

property of material core and cavity size.
 Cooling circuit: In order to reduce the cycle
time, water circulates through holes drilled in
both the core and cavity plates.
 Ejection gap: The gap between the ejector
plate face and core back plate face should hold
dimension within the core. It must allow
component to be fully removed from the mold.
Mould Design Consideration
 Mold polishing : The core, cavity, runner and

sprue should have good surface finish and
should be polished along material flow
direction.
 Mold filling : The gate should be placed such
that the component is filled from the thicker
section to thinner section.
 Draft: Required in both the core and cavity
for easy ejection of the finished component.

Mould Storage
 Manufacturers go to great lengths to protect
custom moulds due to their high average
costs.
 The perfect temperature and humidity level is
maintained to ensure the longest possible
lifespan for each custom mould.
 Custom moulds such as those used for rubber
injection moulding are stored in temperature
and humidity controlled enviornments to
prevent warping.
Mould Cooling
 Constant mold temperature for uniform quality
 Reduced cycle time for productivity
 Improved surface finish without defects
 Long mold life
 Avoiding warpage by uniform mold surface

temperature (warpage caused by nonuniform
cooling)
Mould Cooling
Moulding Defects
 Blister
 Flash
 Burn marks
 Warping
 Weld lines
 Colour streaks
 Voids
Manpower
 To set up process
 To monitor process and troubleshoot
 To operate machine
Injection Moulding Used For
 Plastic Injection Moulding
 Rubber injection Moulding
 Metal Injection Moulding

Plastic Injection Moulding
 It is a manufacturing process for producing
components by injecting polymer material into
a mould.
 Thermoplastic and Thermosetting plastic
material are used.
 Thermoplastic materials are reusable.
Applications
 Writing instruments components ( pen barrel,
cap, bush etc)
 Computer Electronics
 Automative Components
 Aerospace Components
 Electronic Components
 Toys etc.
Rubber Injection Moulding
 Injection molds can make many rubber

components. It makes valve steam seals, oil
seals for engines, telecommunication items
etc.
Metal injection moulding
• Injection molds can stamp out small to large
items. It can stamp out automobile parts from
spark plugs and floor pans to ball bearings. It
also can stamp out items like TV hangers
and knitting needles.
Advantages Of Injection
Moulding
 Fast production.
 Low labour costs.
 Design flexibility.
 High-output production.
 Multiple materials can be used at the same time.
 Can be used to produce very small parts.
 Leaves little post-production scrap.
 Ability to include inserts.
 Good colour control.
 Good product consistency.
 Reduced requirements for finishing.
 Good dimensional control.
Disadvantages Of Injection
Moulding
 High initial tooling and machinery cost.
 Part design restrictions.
 Small runs of parts can be costly

Applications Of Injection
Moulding
 Injection moulding is used to create many
things such as Cups, Containers, tools,
Mechanical parts (Including gears).
 Injection moulding is the most common
modern method of manufacturing parts. It is

ideal for producing high volumes of the same
object.
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INJECTION MOULDING

What Is Injection Moulding?

 HDPE( High density poly ethylene)

 LDPE(Low density poly ethylene)

 Mould holding and cooling

 Shrinkage allowance: Depends on shrinkage

 Mold polishing : The core, cavity, runner and

for easy ejection of the finished component.

 Improved surface finish without defects

 Long mold life

 Avoiding warpage by uniform mold surface

 Metal Injection Moulding

 Injection molds can make many rubber

 Small runs of parts can be costly

modern method of manufacturing parts. It is

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