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Injection molders typically rely on outside mold builders to custom-build molds for their clients. Molds rarely arrive with perfect dimensions; typically, after the mold is received, checked out, and tested, adjustments need to be made to the mold to assure all design specifications are met. For most injection molders, this requires sending the mold out for those final adjustments, which burns up a lot of valuable time. Kaysun, however, has the ability make these adjustments in-house and “fine tune” molds after initial sampling to modify the mold core/cavity geometry and achieve the desired dimensions.
Injection-molded plastic components and devices have long been the choice of medical manufacturers for projects requiring tight tolerances, complex product geometries and lightweight versatility. This level of confidence is credited to things like trusted designs, past performance and partnerships with experienced injection molders, but one key contributor to production consistency that is often overlooked is moldflow analysis.
Customers count on their injection molders for expert advice. “Tight tolerance” is a term that is often tossed around loosely in the industry—however, if it’s not done right, parts and products will underperform or possibly fail, resulting in a tooling and/or process overhaul. Therefore tight tolerance is serious business, especially for complex, mission-critical parts.
The quality of plastic components is, in part, determined by the injection molding partner you choose. Properly vetting new, different or specialized vendors involves qualifying a pool of potential molders based on your project needs — i.e. ISO and other certifications, design capabilities, clean room specifications, and value-added services like assembly and overmolding. However, taking the vetting process one step further by conducting on-site quality audits will reveal which has the right level of expertise, facilities, and quality procedures in place to deliver to specific project requirements.
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.
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.