The Key to Scientific Molding is Engineers who Specialize in it

Posted by Kaysun Corporation on May 19, 2015 9:54:34 AM

May 19, 2015 9:54:34 AM

Much has been said about the ability of scientific molding to provide optimal control of the injection molding process – and in turn – help manufacturers of critical use-devices that contain precision-molded parts keep pace with competition and be the first to market. But what some wonder is what really makes scientific molding work in the first place. And the answer is the engineers who specialize in it.

When performed by molding personnel with thorough training and the proper certification, scientific molding virtually guarantees top quality by removing all guesswork from the injection molding process. The aim is to develop templates for repeatable production.

Here’s a look at the phases of scientific molding and the role that specialized engineers play to ensure success.

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Topics: Scientific Molding

The Future of Medical Injection Molding

Posted by Kaysun Corporation on Apr 23, 2015 2:53:22 PM

Apr 23, 2015 2:53:22 PM

Advancements to polymers and injection molding technologies have contributed to widespread adoption of plastics in the medical industry. All segments of the medical industry have embraced the benefits of plastics. Low cost plastics have enabled the creation of disposable plastic instruments, syringes, gloves and gowns that in turn helped reduce the spread of infections within the hospital environment.

High performance polymers contribute to the longevity and friction-free movement found in current generation artificial joints. Handheld medical devices and instruments use plastics to reduce device weight, improve functionality or lower device cost. Plastics have replaced glass in a variety of laboratory consumables, improving lab safety while reducing consumable costs.

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Topics: Injection Molding

Benefits of Injection Molding Surgical Devices

Posted by Kaysun Corporation on Apr 3, 2015 2:32:20 PM

Apr 3, 2015 2:32:20 PM

Medical grade polymers are quickly becoming the preferred material for a broad range of surgical devices. In certain applications, the robust mechanical properties of medical polymers allow complete removal of metal from the surgical device design.  In other instances, plastic and metal components can combine to create an enhanced product, with attributes that would not be possible in either an all-metal or an all-plastic device.

Incorporating plastic into surgical devices offers a number of benefits including reduced cost, improved ergonomics and increased functionality.  Below are some of the main reasons to consider injection molding for surgical devices:

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Injection Molding Expertise - Worth its Weight in Gold

Posted by Matt Fehrmann on Feb 16, 2015 12:05:00 PM

Feb 16, 2015 12:05:00 PM

Injection Molding Expertise

It would be almost impossible to conceive of a world without plastic injection molded components. They turn up in just about everything we use, and most of us aren’t even aware of the amount of technical expertise that has been used to produce them. From the first glimmer of an idea to the production of the finished product, there is a chain of knowledge that has been incorporated into their design and manufacture. This process does not happen by chance; it is the culmination of many years of experience by highly trained and skilled designers and engineers.

Finding the right combination of injection molding experts under one roof is essential to successfully completing a production job. The molding company must be knowledgeable about the raw material, the variations in the molding machines, and the design of the mold. Every injection-molded component is different, and each has its own set of variables that the injection molding company must understand.

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Topics: Injection Molding

Plastics in the Automotive Industry

Posted by Matt Fehrmann on Feb 9, 2015 2:36:00 PM

Feb 9, 2015 2:36:00 PM

A Solution to a Weighty Problem

More than ever before, automakers are under the gun to improve their car’s efficiency by increasing the fuel economy for all models. In 2012, President Obama finalized standards to increase fuel efficiency to nearly 55 mpg for both cars and light-duty trucks by 2025.

Although there are several ways to achieve this goal, reducing the car’s weight is one of the best – and easiest – ways to improve fuel economy without compromising other design and safety factors. And one of the heaviest components of any car is the powertrain. The powertrain’s weight contributes a disproportionate amount to the car’s overall mass, making the powertrain an area of focus for today’s aggressive automotive part injection molders.

The powertrain is one of a car's most complicated assemblies; it refers to the system of bearings, shafts and gears that transmit the engine’s power to the axle. Recently developed plastics materials can help reduce the number of parts needed to assemble these complex components while also reducing overall vehicle weight.

Plastic is Preferred 

Gone are the days when plastic was considered a cheap alternative to non-critical automotive components. Automotive engineers are combining plastics’ unique and variable properties to perfect designs and to improve their products’ efficiencies.

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Customer Service Can Make or Break a Company

Posted by Mary Stuiber on Sep 11, 2014 1:12:33 PM

Sep 11, 2014 1:12:33 PM

Customer service is an integral part of every organization. Deals can be won or lost through the communication process. Honest communication, with the customer’s best interests always at the forefront—from the initial contact of the pre- sale to the support after the sale—is the cornerstone of good business practice.

With the technology we have today, customer service comes in many forms—face-to-face, phone, e-mail, Skype, the web, etc. And customer service isn’t limited to a call center or customer service personnel—any employee who interacts with a customer is a customer-service representative. It is ideal for account executives or project personnel to meet with customers face to face throughout the year, with frequency determined by customer preferences. It is important to stay connected on a regular basis to make sure you understand their needs, desires, and concerns (which can shift quickly, depending on the project or the market). Whether it is daily, weekly, or monthly dialogue, everyone needs to stay in the loop.

Excellent customer service is essential for:

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Topics: General Manufacturing

High-Quality Partnerships Improve the Bottom Line

Posted by Al Timm on Sep 10, 2014 3:27:30 PM

Sep 10, 2014 3:27:30 PM

“Little” things matter when it comes to overall efficiency, productivity, and quality. Of course, having the best equipment and technologies, materials, know-how, and training is a given. But efficiency and productivity are always enhanced when injection molders and their customers know each other well as partners and work together as a team. They share the same strategies. They know how the other thinks and operates and reacts. As partners, they deepen their relationships over the long term, because they know they are stronger together.

When a customer decided to partner with a high-quality injection molder, great things can happen. For example, project lead times can be shortened. Depending on the size and complexity of the project, as much as two weeks can be saved for a simple part, or many months for larger complete assemblies. This makes a big difference in time to market.

Key factors that contribute to shortened project lead time are:

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Topics: Plastic Part Design

Non-Uniform Wall Thicknesses Can Create Quality Problems

Posted by Ken Glassen on Jul 22, 2014 2:26:51 PM

Jul 22, 2014 2:26:51 PM

Designing wall thicknesses that are as uniform as possible helps control the shrink rate for that part or product. Shrink rates for different materials vary according to wall thickness of the part. Non-uniform walls can lead to large pressure drops during filling, causing significant differences in shrink rates. In turn, varying shrink rates cause internal stresses within the part, leading to warpage.

For example, thicker areas in the part can act as “runners” within the part that alter the way the plastic fills the mold. The molten plastic prefers to follow the easiest path, so its flow will always favor the thicker wall section first. As a result, molten material may race ahead in some locations, and then “backfill” the remaining space. This can be troublesome, especially if adequate venting has not provided in these areas to allow the escape of any trapped air.

When gating a part, it is important to gate into the thickest section and then flow into thinner areas. This is necessary to properly pack the part out after filling. The flow path of molten material must remain open so the plastic material can continue to flow into the part details during the cooling phase. Gating into a thin wall, or flowing through a thin area to get material to a thicker area, may create flow irregularities. The thinner area may freeze and solidify, preventing the additional material in the pack phase from reaching the thick section of the part. This can cause higher shrinkage due to the underpacked conditions in the thick area, resulting in sink and/or warp in the part.

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Topics: Plastic Part Design

Shrink Rate Has a Big Impact on Quality

Posted by Al Timm on Jul 22, 2014 1:51:32 PM

Jul 22, 2014 1:51:32 PM

Not taking the time to properly determine shrink rate can have a big impact on the quality of the final product—including its geometry, performance, and appearance.

Material suppliers typically provide information on the shrink rate of their materials. This number is usually based on ASTM Standard D955 and a .125-inch thick plaque with a specific gating size and location. Although this is a good place to start, this value is typically not accurate enough for many products, especially critical, highly complex parts.

Wall thickness of the part, mold gate size, and processing conditions such as packing pressure and mold temperature are major factors in determining shrinkage of the part. For example, thinner wall sections cool faster, resulting in less shrinkage. Larger gates will result in longer packing time, also providing less shrinkage.

Shrink rates also vary according to flow direction. After gate locations are selected, it is important to analyze the part to determine the basic direction of flow. On long, narrow parts—gated at the end, for instance—flow will essentially parallel the length of the part. In these cases, the “in-flow” shrink rate is used for this dimension of the part. The “cross-flow” shrinkage is used for dimensions that are perpendicular to the long dimension. For parts with random fill directions, an average of the in-flow and cross-flow directions can be used. For parts with critical dimensions, prototyping is the safest option (the mold can be also left steel-safe so that critical areas can be “tweaked” if needed after a production molding process is established).

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Topics: Injection Molding

Up-Front Collaboration Helps the Environment, Too

Posted by Al Timm on Jun 24, 2014 2:19:30 PM

Jun 24, 2014 2:19:30 PM

There are plenty of great production reasons for getting together with your injection molding team during the earliest design stages to discuss design for manufacturability (DFM). It is also a great way to help the environment.

We all have a stake in doing whatever we can to protect our natural resources, water, and air. That’s why it is important for manufacturers to be proactive in reducing their consumption of natural resources, production of non-recyclable waste, and carbon footprint—which DFM helps us achieve.

Up-front DFM collaboration with your injection molder brings the best minds together to come up with the best design for your product, as well as the best way to manufacture it.

Take, for example, product design. DFM and computer modeling can identify the thinnest part wall thickness and weight that can still achieve the top performance objectives for that part. This is important—not just for reducing material costs and product weight, but also for keeping you from going with design specs that call for more plastic than is actually required. By using only the amount of material you really need, you conserve valuable, petroleum-based resources and reduce waste/scrap that might be sent to the landfill. You will also be spending less energy to produce the part—another plus for the environment (and the budget).

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Topics: Injection Molding

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