Injection molding has stormed the world with the most incredible precision products. The improvement that injection molding has made in the manufacturing of thermoplastic products is second to none. Therefore, all the industries have not switched towards adopting this method, but they have to be clear about one thing that is mastering this process is the only way to get going with it. If you are not a master at this magnificent innovative injection molding process, you are only going to waste your material. The process itself becomes very easy once you get hold of all the things. Having said that, first, let’s get you familiar with the process of injection molding before jumping onto the tips that will help you in it. What Is The Procedure For Injection Molding? You can say that it is a one-step process because it really is; the entire product is manufactured in just one step. From putting your raw material inside the mold to getting a perfectly shaped final product, all that happens in one go. The pre-process things are what make the most of your time and effort. All of the things that go behind running this process smoothly without any onset complications. The entire process can be divided into three steps. •Designing The Product: This is the initial step of injection molding and also the core step. If the design of your product is faulty, then your entire process will become faulty. You need to design your product by keeping in mind all the dos and don’ts of the injection molding process. However, injection molding has no restriction but still needs to meet certain criteria. You will have to pay close attention to the aesthetics, manufacturability, functionality, precision while designing your product. Only a product design that meets all these criteria will help yield an effective product. •Designing The Mold: After designing the product, comes the second crucial step of this process that is designing the mold for the product. The materials commonly used for making the mold are hardened steel, pre-hardened steel, and aluminum. Among these three, hardened steel is the ideal mold-making material as it lasts longer than the other two. The only drawback is that it is a lot expensive than the other two. in that case, people switch to pre-hardened steel, which is also quite durable but doesn’t last as long as hardened steel. Making the mold correctly is equally important because even if the design of your product is to the point, but mold has faults, then your product will be ruined. •Manufacturing The Product: This is the final step in which it all happens in one go. Your melt thermoplastic and pour this parison into the mold. The machine starts inflating the parison by blowing air into the mold at the center of the parison. Once the parison is inflated enough to achieve its desired shape, it is set aside to cool down with the mold. Upon cooling, it solidifies, and that’s when you remove the final product from its mold. The final product requires no extra machining and has the perfect finish. Tips To Employ In Injection Molding •Selection Of Material: We can not emphasize the importance of selecting the right material for injection molding. Choosing the right material makes a huge difference, more than you think it does. Selecting the right material will let you achieve a fine finish final product. It will also save the money that goes into the extra machining of the final product. Since the right material will help you make the perfect product, nothing will go to waste. •Add Texture Into Your Product: Adding texture to your product adds more appeal; therefore, using this tip will benefit you a lot. You can add texture to your products in two ways. You can either add texture into the mold of your product so that the final product can have it. The other way is to wait for the process to complete and add texture to the final product. •Take Help From An Engineer: To save yourself from spending time mastering the injection molding process, you can also collaborate with an engineer as they are trained professionals in the process of injection molding. An engineer will carry out the entire process for you and make sure that the product in the making comes out exactly like the mapped one. •Pay Close Attention To Wall Thickness: The wall thickness of any product matters a lot; if the wall of a product ends up being too thin, then it would be a fragile product. You can reduce the thickness of the wall to save on some money, but it shouldn’t be reduced to the ideal wall thickness; otherwise, the product will be a waste. Therefore, get to know about wall thickness more to handle this department perfectly.
The blow molding manufacturing of plastic bottles is a widely preferred process for the mass production of plastic bottles. The process itself is highly reliable and there are almost zero chances of any potential hazard in the way of the blow molding process. The products that are obtained through the blow molding process are highly durable and perfectly compatible with the world. However, where blow molding has simplified plastic bottle manufacturing for us there are still possibilities of technical problems which is why certain check and balance has to conduct. To ensure that the product is 100% according to the customer’s demand. One major problem that arises with plastic bottles is the leakage issue. Often when bulks and bulks of bottles are being manufactured there isn’t much time to check each and every bottle to ensure that there is no leakage. However, it is very much necessary to check for leakage in every single bottle. Otherwise, if your customer will fill up a leaking bottle and pile it up with other bottles, the damage that it would cause would be enough to lose him as your customer. You don’t want that, nobody does, therefore what you need to do is to test your bottles for any leak. How Are Leaks Formed in Bottles in Blow Molding Manufacturing? •While testing bottles for leakage, these are the defects that you have to look for: •Bottom blowouts are formed at the base of the bottle due to gross plastic leak; this type of plastic bottle will surely have a leak in it. •When you do not use enough parison for manufacturing your plastic bottle it results in short shots which look like the neck or threads of your bottle are not fully formed, this type of bottle won’t be sealed properly with a cap thereby it will surely leak. •Sometimes some problems come up in the blow molding process due to which the neck of the plastic bottles are not normal but stretched necks. •If your mold has been accumulated by impurities or oil from the hydraulic system, anything that has contaminated your mold will contaminate your plastic bottle and will form a leak in it. •Due to some problems in the blow molding process, you might get nicks and cocked necks in your plastic bottles and these will result in sealing issues. •Some other problems in plastic bottles can be gate leaks, gate cracks, and misformed bottles which will result in leakage. How Can You Test Bottles for Leakage in Blow Molding Manufacturing? The leak testing is done to make sure that none of the product has any defect in it, you can avoid leaks forming your bottles by making sure that nothing goes wrong in the process of blow molding and everything is according to the requirements. The other way is to test for leaks and discard the leaking bottles to be melted again and reused in making bottles. Some ways by which you can leak test bottles are: •When the final product is obtained, check its quality. This will tell you if the bottle is impenetrable or not and can hold pressure or not. A quality plastic bottle doesn’t allow penetration and holds any type of pressure either of the product inside it or of the transportation, it will handle it. •Check for any of the visible defects like cocked necks, gate cracks, misformed bottles, etc. if you find any such bottle which has even the slightest defect discard it. •Have a full inspection process of the plastic bottles. •Keep monitoring the entire blow-molding process constantly so that if any drawbacks occur in the middle of the manufacturing, you can correct them immediately before the full production is done. •After the production is done do the pressure test on each bottle by filling air into the bottle and sealing it. If the pressure of the sealed bottle drops then it has a leak. •The other way of leak testing bottles is by doing a vacuum decay test. If the sidewall of the bottle collapses when it is tested under a fixed amount of vacuum then there is a leak in the bottle. Final Word The role of leak testing bottles in blow molding manufacturing is much needed. This fast mass production of bottles can not only be monitored for leaks but properly tested for any potential leakage. The testing not only helps in shipping quality products to the customers but also helps in avoiding future problems that might occur in the process. All these plastic bottles are used for storing different liquids of different consistency therefore even if a micro-hole that is not visible to the naked eye is present in the bottle it will leak and no one wants that.
The use of a blow molding machine is a process of fabricating items from plastic. The uniqueness of this process is that it is specifically related to the manufacturing of hollow plastic items like jars, bottles, containers, etc. The process goes like this that first, a thermoplastic is melted and turned into liquid completely. This melted plastic called parison is then poured into a mold, where it is then inflated by blowing air into the mold. The inflated plastic is then left to dry with the mold for some time. Perhaps at the end, a hollow plastic item is obtained. This is the entire blow-molding process, but there are a variety of different machines that are used to perform this process. Each machine does the same thing, but differently; this is what creates a slight difference between the obtained products of each machine. With this being said, let's have a look at each machine to understand the difference in their working and functionality. By comparing and contrasting each machine, we will get to know the advantages that each machine produces, and this will aid you in choosing the right machine according to your need. Inverted Head Injection Blow Molding Machine The structure of an inverted head injection blow molding machine is like this that the hydraulics of this are present under the mold sitting at the base of the machine. The presence of hydraulics below the mold is a beneficial thing for getting a high-quality product in the correct desired shape. If the hydraulics are present above the mold like in some machines, then the hydraulic oil keeps leaking into the mold and contaminates the mold or the product. This is why the hydraulic oil, even if it leaks, is far away from getting into the mold or fouling the product. The other advantage of this machine is that since it has a pull-down tie bar system, it is best suited to use for large volumes of material. It can take up to 45 to 205 tons of material. This machine applies pressure directly to the center of the mold, which helps in preventing flexing that can cause the frame to crack; this is another plus point of this machine that you can count on. Hence the ultimate design of this machine is the best and has made this machine the most widely used injection blow molding machine. Inverted Head Hybrid Injection Blow Molding Machine The structure of this machine is similar to that of an inverted head injection blow molding machine. The difference comes here that the hybrid screw of this machine is 100% electric. This difference gives the inverted head hybrid injection blow molding machine the ability to save up to 30% of the energy as compared to the standard inverted head machine. The other benefit of using the inverted head hybrid machine is that its cycle times are faster than the standard inverted head machine. The cycle times of the inverted head hybrid machine are up to 15% faster than the standard inverted head machine. Some additional benefits of this machine that can also be counted are that this machine produces no noise and causes very low pollution. Inverted Head Full Electric Plastic Molding Machine The structure of this is again the same as that of the standard inverted head machine. Like an inverted head hybrid machine, this machine also saves 30% energy and has faster cycles times up to 15%. It also has a full-type hydraulic system. The benefit of this machine is that since it is driven by AC servo motors and controllers for being fully electric, the product that is obtained through this machine is highly stable in its shape and quality. Non-inverted Head Injection Blow Molding Machine This machine is slightly different in its structure from the inverted head blow molding machine series. However, the technique that this machine uses helps it to get the same high-quality products as that of all the inverted head machines. The benefit of this machine is that it is very reasonable as compared to all the inverted head machines. Therefore, if you can get the same quality product from a cheaper machine, then why won't you. This is why this machine is used widely. Final Word The injection blow molding technique has become the mainstream process for making hollow plastic items and has left all the traditional practices behind. This technique gives the ability to make complex designs that were not possible in the past. The strength and efficiency that are obtained by the products through this technique are beyond comparison. The use of machines makes the entire blow-molding process very cost-effective as there is no need for labor in this procedure. The entire process is carried out with the help of a machine. Therefore, fast production of complex plastic items at low cost. This technique is also very environmentally friendly as it produces reduced waste as compared to other techniques.
Plastic molding is a procedure in which liquid plastic is poured into a specific container or a mold to convert it into the desired shape. The use of plastic molding procedures is diverse, and today, they are used in a number of industrial applications. There are various types of plastic molding procedures that can be adapted depending on the required molding setup. There are various types of PP blow molding machines that are widely used for the manufacturing of different plastic products that are available in the market. The other methods of plastic blow molding might include options like extrusion molding, compression molding, and rotational molding. It is a fact that each type of plastic molding has its own benefits in different industries, but one process that has been a popular choice for many industrial applications is nylon plastic injection molding. It has become a go-to option for different industries due to the number of advantages that it provides in ideal substances. Here we are going to take a deep dive into the different benefits of nylon plastic injection molding. What Is Nylon Plastic? Nylon plastic is an artificial thermoplastic polymer that is utilized in the process of injection molding. The artificial thermoplastic polymer was first produced by American chemist Wallace Carothers in the year 1935, and it has been a popular material for the injection molding procedure. Nylon plastic is known to be immensely durable and flexible, making it one of the best options for the molding procedure. Nylon plastic is also known as polyamide. Reasons to choose nylon plastic injection molding. Low Friction The nylon plastic doesn’t heat up easily due to the excellent chemical composition that this material possesses. It is largely used in applications that require a higher amount of application. The lower coefficient of friction in this material makes it highly useful in different injection molding procedures. Due to the versatility that this material has, it can be used in applications such as slides, gears, bushings, and plastic bearings. The low friction element makes it highly compatible with different machines and eases the process of manufacturing in different scenarios. High Melting Temperature Thanks to the chemical composition of this compound, it has a higher melting point. It is a factor that makes it an ideal choice for applications that involve a considerable amount of heating methods. Tensile Strength When it comes to combining other compounds with nylon plastics aids in adding more tensile strength to the material, an example of this can be found in the filling of nylon with glass fibers which makes the resultant plastic less flexible and more brittle. Simpler Combination The flexibility of the nylon plastic makes it easy to combine with other compounds and materials. It is an attribute that makes it a suitable choice for the injection molding procedure with plastic as it involves a number of materials and compounds. When it comes to the manufacturing of different plastic parts, the use of nylon plastic makes it easier to manipulate the manufacturing procedures allowing the operators to take full advantage of the flexibility that the polyamide offers due to its diverse properties. Resistance Plastic nylon has the ability to be resistant to different chemicals, which makes it highly durable and reliable for many applications. Abrasion Plastic nylon is extremely strong and resistant to abrasions and moisture absorption factors. The attribute aids in making the material usable in the case of different complex injection molding procedures. Useful In Manufacturing When it comes to the injection molding procedure, then nylon plastic can be extremely useful in manufacturing different plastic products. The products that are mainly made by using the injection molding process might include plastic bearings, bushings, gears, and other important tools that are found in different engines and machining setups. The plastic compound is also useful when it comes to manufacturing different plastic parts, including the parts that are used in the manufacturing of different automobile parts. When it comes to the manufacturing of identical parts on a large scale, the use of injection molding becomes necessary and different manufacturers opt for the methods that seem feasible in various industrial circumstances. Nylon Plastic In A Nutshell The use of nylon plastic in the injection molding process has its own benefits, and that is solely why more manufacturers are shifting their focus on this plastic compound. It comes at a time when the use of metallic alternatives is becoming obsolete, and manufacturers are looking for far cheaper ways of conduction injection molding procedures. The attributes such as lower friction, higher melting point, higher tensile strength are the key reasons why the use of nylon plastic has become more popular than other methods that are used in the injection molding process.
Stress-free molding is one of the most commonly used methods to conduct the mold stress relief test. It has been used in different industries that deal with the use of any kind of plastic to test out the feasibility and strength that a plastic product can withstand. The stress relief test can be conducted on any element that contains the properties of various forms of plastic, and it has been a groundbreaking testing solution when it comes to the manufacturing of various plastic containers. The equipment used in the stress-free testing might include various kinds of blow molding machinery, which is subjective to the type of product that is involved in the process. The entire process of testing is conducted in a controlled environment, and it’s possible to ensure that everything is aligned before the tests take place. It’s vital to be aware of the characteristics of the material being used in the testing process and have an idea about how the plastic might react in different testing circumstances. The inclusion of different other elements might alter the plastic reactions, so it’s important that the changes in the properties must be noted throughout the stress relief testing procedures. The results might vary depending on the properties of the plastic material, including the hardness or the softness of the apparatus being used in the testing process. The major products that go through a stress relief test when required including electrical equipment, eyeglass lenses, and other appliances. The amount of pressure that each product can withstand might vary depending on their built and the results that are anticipated through the testing standards. There’s also a requirement for manufacturers to make the products depending on the quality standards that are acceptable in the countries where the products are meant to cater to the consumer base. The standards of procedure are often decided by the engineers depending on the specifications of the products and the amount of stress that they can bear without bending and twisting to a point where they cannot be further used for any application. The prime example of this is the bottles that go through several stress tests in a plastic making facility and are monitored so they hold up to the limitation that they might have to depend on the type of plastic that is being used in the manufacturing process. A thorough inspection should take place when the mold parts are in the process of testing to ensure the right amount of precision and accuracy. The tiniest details should be recorded about the changing behaviors and properties of the elements when they come in contact with other elements and molding parts. The closer inspection and controlling tactics might help to get accurate knowledge about the entire stress relief testing process, which might be crucial for different manufacturers who work in the circumstances like controlled temperature and assembly lines. If the inspection is not done in the correct manner, then it might reflect the irregularities in the final product. The blow molding methods have also evolved in recent years with the inclusion of automated blow molding equipment that is built using state-of-the-art technology that enables the operators to receive accurate results without any possibility of error in the procedure. The use of modern technology has helped different industries with less consumption of energy and time; hence the final product turns out to be refined, and engineers are able to conduct thorough testing in a short span of time. Considerations Factors such as the design, cost, and environmental changes all should come into consideration during the procedures of the test take place. There can be a notable amount of disparity when the molding parts are put together with other elements compared to the time when they are being processed in an individual capacity. The main purpose of the stress relief test is to confirm that all the necessary procedures have been done, leaving no boxes unchecked. The stress relief test might expose the factors like how a product has been designed, sourced, and produced in different cases. The design factor of a product might force the operators to take a different approach if necessary as different elements might require several complex procedures depending on the application and the machines involved. What Can a Stress Relief Test Study? The product is removed from the hot oven and kept to be cooled down till it comes to a manageable state. The people involved in the testing process might study the changes and other attributes that might have resulted in the character of a product while it was in the oven. The temperature of the oven might vary between a minimum of 10 degrees and a maximum of 70 degrees, according to the type of the product. The standard time for the testing procedure could go up to 7 hours, while the cooling procedure depends on the type of product that is involved in this test. The time might be changed if the components that are being tested are electric due to the distinguished character of different appliances. The studies might include factors like how the polymers have reacted to the process, how the surrounding elements have complemented the process and if there are any points that might have caused any sort of failure throughout the process. The studies can help the engineers to pinpoint the tiniest details and flaws that might have occurred in the entire process. Potential Results There’s a high chance of different inaccuracies and weaknesses being exposed as the result of stress relief molding tests. There can be many minor irregularities, and some of them are listed below. Warping After a product is exposed to an excessive amount of heat, there’s a high possibility that deformation might occur, and this deformation is known as warping. It can cause changes in the structural properties of a product and might result in some kind of damage. The damages that may occur during the procedure might include twisting, bending, distortion on the edges, and raising of a product from the sides or the edges. There can also be a possibility that warping might occur through the moisture without any direct involvement of heat in the process. There are many other elements that face warping with just the involvement of heat without any exposure to the moisture. If any signs of warping are indicated in the process, then the operators might stop the procedure halfway through and examine the exterior of the product to determine the potential causes of warping. The engineers might be able to find their way through the root cause in which they can point out the potential imbalance of mixtures or the irregularities in the polymers that are involved in the stress relief test. Different methods and techniques are used depending on the behavior of polymers so that accurate outcomes can be found and possible solutions can be considered. Procedures such as the Attenuated Total Reflection have been tried and tested in many different circumstances to examine each component of polymers involved in the process. The weaknesses can be easily pointed out if the signs of warping are detected earlier in the testing procedures. The engineers go as far as examining the polymer mixture used in the process when it comes to acknowledging the tiniest details. Shrinking The shrinking doesn’t usually happen after few hours of the product being placed to be cooled down after the heating procedure. The main reason behind the shrinking is the imbalanced polymers, and it can happen up to 20% in a testing process. The shrinking might result in various visible issues that might occur when it comes to tallying the product with the rest of the system. Cracking Cracking is a unique phenomenon that takes place if the polymers produce an unsatisfactory amount of brittle plastic. Although the procedures are done in a controlled setting but sometimes due to the exposure to an extra amount of stress through machining, different cracks might be evident in the final product. It can instantly provide the engineers an idea that the formulation is weak and there’s something wrong with either the reaction of the polymers or the mixture involved in the process. The cracking might be a result of several factors, including the small broken polymers or the cooling of enclosures at a relatively fast rate compared to the others or any involvement of pressure in the process. Residue Stresses The residue stresses are the real perpetrators behind the weaknesses that might occur during the methods performed in the test. In the case of the stress relief test, the load that is removed from the process is the extreme heat that might result in several weaknesses and irregularities dictating the outcomes of the stress relief test. The engineers ensure that the weaknesses are overcome to make the process seamless and perform the testing in the correct manner. The residue stresses of all kinds are reduced by checking all the necessary apparatus, including the polymer mixture, heating, and cooling temperatures.
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In the four-day exhibition, a large number of people came to visit the booth of Leshan, visiting the Second-generation Athlon EBM Machine and learning more information about it. The Second-generation Athlon EBM and the Tornado Electric EBM Machine were two stars in Leshan’s booth. The new Athon is a machine that manufactures a 3-litre cleaning supplier with a 22-second cycle time (23,500 pcs/day). A new design, Swimming-arm Robot hand with servo-motor is equipped into the machine after being tested over 5 million times. Highly delicate die head design and stable productivity are the representatives of Leshan’s efforts in the plastic industry in the past years. Leshan is sincerely thankful for all customers who spare time for our exhibition, coming with troublesome problems and leaving with pleased solutions. It’s our pleasure to have an opportunity to solve problems for customers, and we appreciate your trust and support for us. With 20-year struggling, Leshan Intelligent has grown up to a company in the plastic field with abilities of research and development, exploration, and providing solutions for customers all over the world.