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In this age of global competitiveness and tough regulation, superior quality is the name of the game in differentiating you from competitors and increasing your market share.
OEMs in various industries are designing increasingly complex components, products and devices with higher injection molding tolerances that must meet stringent quality standards, regulatory compliance and cost-effectiveness. This can be achieved through scientific molding, the best designed and controlled manufacturing process possible.
It’s a world of handheld devices we live in today: smartphones, tablets, GPS assistants and specialized power tools for the shop, lab, kitchen and garden. Medical facilities depend on portable digital devices to care for patients, contractors align studs with pocket-sized levels, troops perform safely in the field with reliable, high-performance equipment and gear, and households are stocked with all kinds of gadgets that make life easier.
Metal-to-plastic conversion is a decades old concept, and it remains a popular option for addressing concerns about component or end product cost, weight, manufacturability and compliance. While metal-to-plastic conversion is effective, many industries — notably automotive, defense and medical — are leaning into it further in order to reap more benefits by consolidating multiple existing parts into a single complex injection molded plastic part.
It seems old-fashioned to load anything by hand these days, especially in a high-tech industry like injection molding. However, “hand loads”—mold inserts that are physically placed into a mold and then removed when the part is finished—are essential for the production of certain parts.
There are many factors that impact injection molding tolerances—all of which need to be controlled with precision to meet final part specifications. The greater the number of factors, the harder it is to achieve tight tolerances consistently. That’s why it is so important to consider tight-tolerance requirements during the plastic part design process, where factors can be addressed through design modifications without impacting quality or performance. In fact, working with an experienced injection molder like Kaysun could actually result in even tighter tolerances, if needed, through expert alignment of design, materials, tooling and production process parameters.
As criticality of use ratchets up on injection molded products and devices, plastic components are expected to perform to stringent quality and regulatory standards.
Scientific molding is the best way to deliver complex, high-performance parts. It is a highly precise, data-driven process that eliminates any guesswork and maximizes quality and manufacturability. Scientific molding is especially valuable when it comes to decisions about process optimization, molding and tooling design validation, and product quality.
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 molding 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.
Complex injection molding projects are, by nature, an expensive undertaking. Part development and injection mold tooling design/build often account for the majority of the budget, particularly in the case of intricate components. The consistency and quality of the part produced hinges on optimizing part development and injection mold tooling performance, as does overall project cost. Missteps can lead to expensive setbacks, product defects and quickly evaporating profits.