What is the process by which the plastic molded products we manufacture are made? I would like to introduce the process by which the plastic molded products we manufacture are made.
First of all, we need to know what kind of product and shape it is, and for what purpose it will be used. We also need to consider the materials to be used, the number of production units, production bases, etc.
(1) Determine the product shape
First, determine the shape of the product. In recent years, with the availability of 3D CAD, it is possible to grasp the shape of the product while rotating it on the PC screen.
In this case, a flat plate for shrinkage measurement is used as a model.
Related Articles → Molding Shrinkage of Plastic Products
(2) Plastic Material Selection
Plastic materials have various characteristics, and materials are selected according to their electrical properties, abrasion resistance, impact resistance, sliding properties, dimensional stability, and other properties to suit the application. If rigidity is required, glass fiber or talc may be used in the mixture.
Image of resin pellets (in granular form for easy molding)
It is important to note that the higher the material's rigidity and other physical properties, the greater the impact on the mold during molding.
damage to the mold during molding. In other words, the frequency of mold maintenance increases. In the case of mass production of materials containing glass fibers, molds are often quenched.
Related articles → Characteristics of molding materials and key points of molding
(3) Determination of gate position
Once the product shape and materials to be used are determined, CAE simulation is performed to see if the combination of the materials and product shape will really produce a molded product. Mainly, flow analysis software is used.
If the product cannot be filled completely or if the injection pressure is too high, the gate thickness and layout are adjusted so that the product can be molded without difficulty.
This series of work includes not only the gate position and gate thickness, but also the selection of the molding machine to be used, such as the required mold clamping tonnage.
We can also select the molding machine to be used.
If there is a slight change in the shape of the product, such as a design change, it is recommended that flow analysis be performed again.
Related article → What flow analysis can tell us
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