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Surface finish on plastic composites can vary a great deal, depending on the physical and chemical properties of the polymer blend, as well as the parameters of the injection molding process.
The first objective is working with the client to determine how important the surface finish is for the appearance and/or performance of the final product. For example, does the product need to be eye-catching or simply functional? Depending on the answer, the material selected and the desired finish will determine the settings for the injection molding process, as well as any secondary finishing operations that might be required.
Medical OEMs make device reliability a top priority, working with complex injection molders that are experienced in scientific molding to ensure accuracy in processes and production. The higher level of precision helps minimize overall costs by allowing for identification and correction of problems prior to production.
Geometric dimensioning and tolerancing (GD&T) is a symbolic language that is used on engineering drawings and computer-generated models to communicate geometric dimensions and allowable tolerance for various parts. Not only is this a useful exercise for product design, it’s also helpful on the manufacturing floor because engineers and operators can quickly see the degree of tolerance that is required for each part.
Commodity plastics are versatile materials appropriate for a breadth of applications. However, specialty or complex injection molded parts like those required for medical, fire, and safety industries may contain requirements that mainstream polymers can’t fulfill, such as chemical resistance, fire retardant properties and mechanical grade strength.
Controlling costs is a huge part of any project. Materials can be expensive, especially advanced or specially-engineered resins, so you want to get as much bang for your materials buck as you can. One way to do this is the proper use of regrind.
There is always some unused thermoplastic material that is left over from injection molding, typically taken from mold components such as gates, flash, runners, and sprues. What's the point in wasting it.
Critical-use medical devices are essential in the performance of important and often life-saving tasks. As such, they often boast complicated designs and functionality that require the expertise of a complex injection molder to produce. However, that’s only part of the equation.
The complexities of engineering a plastic part or product for use in a critical-use application must translate to moldability. If a molder is inexperienced in mold design and process optimization, there’s a good bet they won’t be familiar with methodologies essential for creating a highly efficient production process such as scientific molding and, more specifically Design of Experiments (DOE) within scientific molding. This article discusses key steps tool and process engineers take to ensure consistent and repeatable manufacturability of flawless molded parts.
There are several options for prototyping your designs—the one you choose really depends on what you expect to accomplish with the prototype. For example, is the prototype just for show or will it be subjected to some testing? The most common prototyping options are SLA/SLS, urethane cast, soft tooling, and hard tooling. But which is right for your component? Read on to discover the advantages and disadvantages of each.
Manufacturers of medical devices and other medical applications often turn to a complex injection molder for help correcting defects in their engineered plastic components. At Kaysun, we actively seek to prevent defects before they even occur by using a design for manufacturability (DfM) approach that incorporates a comprehensive mold flow analysis and extensive plastics engineering experience to identify any potential issues in the design phase and determine the best strategy to produce defect-free parts.