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Plastics Discovery Tour

Fakuma

 for plastics. As simple as injection molding may seem at first glance, a closer look at the process reveals its 

. This article describes the injection molding 

 in an easy-to-understand way and provides an 

Injection  Molding - The processed plastics

A variety of thermoplastics, thermosets and elastomers are suitable for injection molding. 

 such as polyamides are available specifically for the injection molding of 

 suitable for injection molding include a range of 

 are suitable for silicone injection molding.

The following list contains a selection of plastics suitable for injection molding and their abbreviations:

Depending on the requirements and intended use, selected thermoplastics such as polyamides and high-performance plastics such as polyphenylene ether blends are used for processing glass fiber reinforced plastics (GRP) in injection molding.

A typical material for glass fiber reinforced plastics is, for example, PA 6 GF30% (polyamide 6 with 30% glass fiber), which is used for electronic housings or machine elements, among other things.

Plastic injection molding, also known as injection moulding, is a 

. It is particularly suitable for the production of 

. The main reasons for this are the positive process characteristics, including: 

The range of injection molded parts extends from the 

. The weights of the molded parts range from 

Injection molding machines generally consist of two parts: 

. In contrast to the extruder, the injection molding machine produces its molded parts 

 or injection molding cycle comprises the following steps:

For injection molding, it is necessary to 

 the plastic supplied by the raw material manufacturer, usually in 

 (plasticizing). This takes place in the injection unit. Its extruder conveys the granulate and melts it through 

During plasticizing, the rotating screw conveys the melt forwards. Pressure builds up in front of the screw tip. This causes the screw to be pushed backwards. Back pressure is applied to make it more difficult for the screw to move backwards. This means that the screw is pushed back during dosing to the extent that melt is formed. This not only makes it more difficult for the screw to move backwards, but also improves the homogenization of the melt.

Briefly explained: Back pressure during injection molding

 (melt) is then injected into the injection mould under pressure. The surface 

 of the finished part are determined by the 

, the tool is cooled so that the melt cools as soon as it enters the tool. When the temperature falls below the 

 (glass transition or crystallization temperature), the mass 

, which is compensated for by further melt delivery in the 

 (e.g. rubber), the injection mold is heated, which initiates the cross-linking process.

Once the holding pressure phase is complete, the melt for the 

. The final process step in injection molding involves 

 has become increasingly established as a plastics processing method and is 

 in particular. The question of which manufacturing process is best suited cannot always be answered unequivocally. Initially, 3D printing is significantly faster than injection molding. For larger quantities, injection molding is generally the more cost-effective process - despite the high cost of the tool.

 used make this plastics processing method a real 

. From the food industry to the automotive industry - in almost 

, we encounter products made from plastics that have been created using injection molding.

However, this is also associated with certain problems. Plastics are designed to be 

, even if this unfortunately does not always apply to all products. But the industry is responding to this. Injection molding with 

 are two approaches to making products and applications more 

1st edition, Carl Hanser Verlag, Munich (2024)

2nd edition, Carl Hanser Verlag, Munich (2020)

Einführung in die Kunststoffverarbeitung

8th edition, Carl Hanser Verlag, Munich (2017)

Specialists Article online (German language), 

www.form-werkzeug.de/a/grundlagenartikel/werkzeugaufbau-von-spritzgiesswerkzeugen-224057

Injection Molding - the most important processing method for plastics | Process Technology ✓ Tools ✓ Materials ➤Get informed now!

Injection Molding | Processing Technology

The plastics industry's demand to produce 

 as cost-effectively and resource-efficiently as possible is constantly presenting machine and plastics manufacturers and processors with new challenges. Through process and 

, injection molding offers a wide range of possibilities for mastering these challenges. A broad and constantly growing range of 

 that differ in terms of color or mechanical properties, for example, are processed. If two materials are combined with each other, this is referred to as 

. 2K stands for “2 components” that are joined together in the injection mold.

With multi-component injection molding, plastics processors have the opportunity to produce molded parts cost-effectively in a 

, while integrating functionalities such as design, haptics, sealing function or injection molding assembly. The advantage is that - contrary to what one might initially think - only 

Thermoplastic foam injection molding (TSG) is a 

 that has been established for many decades in which the plastic melt is provided with a 

. This allows it to foam up after entering the cavity. To ensure that the molten plastic has enough space to foam, the cavity is usually only 

Compression molding is a special process that is used for injection molding with 

. As the name suggests, the basic form of this special process is a 

combination of injection molding and embossing

, in which an embossing tool is pressed into a plastic surface under pressure. The aim of compression molding is to achieve 

The central component in injection molding is the 

. It is not part of the machine and must be 

 for each article to be produced. Errors made in the tool design have a 

The basic tool design for injection molding machines is identical. Each injection mold consists of two halves: a 

Core pulls are part of the machine equipment, but control mold elements such as cores, slides, jaws, etc. A hydraulic core puller is always used in injection molding when an element (core) has to be pulled out of the mold and cannot be controlled mechanically via the opening movement.

Briefly explained: The role of the core pulls

When we talk about a single, double or quadruple cavity injection mold, we are referring to the number of cavities. In 

and form the same molded parts or can be 

 and form several different geometries during a single cycle.

During the injection phase, the melt is pressed through the 

 and fed into the molded part through the gate. The resulting 

 of sprue for injection molding with plastic:

Cold water can be fed directly through the mold as a cooling medium for 

during injection molding. However, the majority of injection molds are 

 to a temperature between 40 and 80 °C using 

. Technical thermoplastics even require temperatures of up to 200 °C.

. The circuits into which the conventional temperature control units are integrated in the injection molding process can be operated open or closed. Oil is generally used in 

Injection molding is one of the most important processing methods for plastics. As simple as injection molding may seem at first glance, a closer look at the process reveals its complexity.

RJG, Inc. introduces CoPilot Go – a new feature that enables molders to conduct tool trials and contain defects quickly without interfacing with the injection molding machine.

The new feature CoPilot Go  enables molders to conduct tool trials and contain defects quickly without interfacing with the injection molding machine.

Spritzgießen

Spritzgießmaschinen, allgemein

Spritzgießmaschinen

Spritzgieß-Zubehör und Einzelteile

Improving Part Quality and Minimizing Defects

Recent studies show that the blowing agent content and expansion ratio during negative molding offer the greatest potential for optimization in order to achieve reliable and reproducible foam structures.

Sample section of an expanded, glass fiber-reinforced PP-GF30 foam plate. 

16:9

Investigation of thermoplastic foam morphologies under the influence of the manufacturing process using x-ray computed tomography 

Schaumspritzgießen

Computer-Tomografie-Systeme

Qualitätssicherung Kunststoff

Non-Destructive 3D Analysis  of Foam Structures

Machine vision MoldWatcher prevents tooling damage and detects short shots in medical molding operation.

MoldWatcher machine vision prevents tooling damage.

Bildverarbeitung

Bildverarbeitung, Machine Vision

Medizintechnik

Proactive Mold Protection

Pollmann is the first automotive supplier in Europe to purchase an Allrounder Cube injection molding machine. Cube mold technology and machine design enable enormous output.

The Allrounder Cube and the 4 × 16-cavity cube mold can produce 16 million parts per year. 

Spritzgießwerkzeuge

KFZ-Zulieferer

Firing on All Four Cylinders

How Weiss Kunststoffverarbeitung GmbH & Co. KG in Illertissen, Germany, developed from an extended workbench to a system supplier in 80 years.

At a high level: The ride-height control housing for trucks must withstand 11 bar pressure. Nine parts are ultrasonically welded in the assembly line and subsequently tested for leak tightness.

Strategie und Organisation

Schröder, Susanne

“We Must Go to the Limits  of What Is Feasible”

PA particle foam (EPA) has better properties than conventional polymer foams. Components made from EPA can also be overmolded with PA.

The relatively large-volume EPA core (left) can be overmolded. This extends the design freedom and enables large-volume but comparatively lightweight components (right).

Schaumstoffe und Vorprodukte

Partikelschäumen

Schaumstoffe

Polyamide

Kunststoff Werkstoffe

Technische Kunststoffe

Overmolding PA Foam with PA

Needle, pin and rotary shut-off nozzles offer tailor-made solutions for various injection molding applications. From processing low-viscosity to highly filled plastics, they are precisely tailored to the respective requirements.