Just as with overall product design, mold design is another opportunity to prevent defects during the injection molding process. We have previously written blogs on the Top 10 Injection Molding Defects and Avoiding Mistakes in Injection Molding, but here are some examples of how poor mold design can be a costly mistake:

Not designing the proper draft: This refers to the angle at which the finished product is ejected from the mold. An insufficient draft can lead to ejection problems, costing significant time and money.

Improperly placed or sized gates: Gates are the openings in a mold through which thermoset or thermoplastic material is injected. Each will leave a vestige (scar), which can create aesthetic or functional problems if not properly placed.

The number of parts (cycles) required, as well as the material they will be made of will help drive decision-making as to how and with what materials to create the mold.

When a product has been properly designed, approved, and die cast, it’s time to start the actual manufacturing! Here are the basics of the injection molding process…

Thermoset or thermoplastic material in granular form is fed through a hopper into a heating barrel. (Learn more about the differences between plastics in our PLASTICS course.) The plastic is heated to a predetermined temperature and driven by a large screw through the gate(s) and into the mold. Once the mold is filled, the screw will remain in place to apply appropriate pressure for the duration of a predetermined cooling time. Upon reaching this point, the screw is withdrawn, the mold opened, and the part ejected. Gates will either shear off automatically or be manually removed. This cycle will repeat over and over, and can be used to create hundreds of thousands of parts in a relatively short amount of time.

1.Providing better lubrication and lower lubrication consumption. A smooth operation leads to longer lifetime of the clamp. Less maintenance required.

2.Due to new toggle design with optimized kinematics.

Take 200-ton clamping unit for example

Vm: Moving speed of movable platen

Vo: Moving speed of oil cylinder

3.The rigid one-piece injection base supports the common slide rail for injection and screw movements.

4.Highly optimized servo-hydraulic technology, with improved efficiency for lower energy consumption.

5.The technologically matured Jupiter II Series convinces not only with rapid, smooth mold movements and its highly economical energy consumption. The latest upgrade to the Jupiter - called “Plus” - has brought significant additional improvements.

6.FOUR SHORT STROKE MOLD BREAK CYLINDERS

For accurate mold height control with closed loop position feedback, ensures the mold is clamped with parallel movement.

7.HIGHLY RIGID INJECTION UNIT GUIDANCE

with independent movement of the screw drive support.

8.The Hydraulic Units

High efficiency, Energy-saving and high precise proportional pressure and flow variable displacement pump system make the out of the hydraulic system matching the required power for entire machine operation without loss of high pressure throttle and overflow energy. As comparedwith constant displacement pump, it saves power by 30%~60%. A motor with same power may be fitted with an oil pump of bigger displacement and thus accelerates the speed of machine.Besides, the low oil temperature will prolong the service life of sealing elements.

Buffer device is used in every mold opening and clamping oil way to ensure steady mold opening and clamping operation without any impact.Besides, differential mold clamping operation is fitted to ensure high production efficiency.

9.The Machine Introduction

The machine use the high-performance servo dynamic control system,the oil pump as the power source,having the characteristics as follow:high response,saving energy, low noise, high-control precision, and have the breakthrough in the prefect connection of the electrical servo and hydraulic drive system.