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Converting metal parts to plastic is becoming an increasingly standard practice in a number of industries from automotive to defense and public safety. The decision to use plastic instead of metal seems like a no brainer given the many advantages like lighter weight, lower material costs, quicker manufacturing times and extended tooling life.
While the injection molding process is a mainstay for many industries, it isn’t static. Molders are continually challenged with evolving their knowledge and use of emerging tooling technologies, materials and trends to make products that are competitively advantageous and profitable for manufacturers.
Faster time to market is a distinct competitive advantage, but making speed a priority can jeopardize injection molding process efficiencies — and your product performance.
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.
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.
Complex injection molders entrusted with producing plastic components for medical and other critical-use applications assume a high degree of responsibility to ensure the device performs properly, without fail in sometimes life-endangering situations.
Injection molding is a complex, dynamic system with multiple, interacting factors—all of which impact performance, cost, and quality. One of these factors is the tonnage calculation, also known as the clamping force of the injection molding machine.
Plastic automotive components can be susceptible to rework, rejection and budget-breaking increases in total cost of production if the parts used contain molding defects. Often these defects evidence themselves during end product review — when it could be too late for a remedy.