Injection molded parts and products are common in many industries, so much so in fact that commodity molders are often the go-to for injection molding projects. This can be the appropriate choice in many cases, but for industries requiring specialized devices and components, no aspect of a project can be left to chance. This is especially true in the case of resin selection, since the plastic used in production largely dictates how a part or product operates within the end-use environment. Knowing this information is imperative for critical-use applications, where risk mitigation and performance are paramount.

May 7-11 found thousands of professionals from across the plastics industry and all of its vertical markets gathered at NPE2018: The Plastics Show (NPE®) — the world’s leading plastics trade show and conference.

In Part 1 of our short blog series, we discussed the differences between today’s thermoplastics and liquid silicone rubber (LSR) thermoset resins, as well as their common advantages, disadvantages, and applications. In Part 2, we’ll talk about some of the up-and-coming plastic materials making their way onto the injection molding scene, specifically carbon fiber composites and bioplastics.

The plastics industry has been experiencing rapid growth since 2015. In that time, there have been numerous improvements to the materials, technology, and processes used, benefiting both manufacturers and consumers alike. The development of stronger, more lightweight plastics and thermoplastics has been one of the driving forces of growth, along with the use of recycled plastics and greener processes.

Are you considering injection molding for the production of a current or upcoming plastic parts project? If so, you came to the right place. Injection molding is the ideal process for the production of a wide range of complex plastic components, and can benefit OEMs across many different industries. It’s consistent, affordable, and creates durable, high-quality plastic parts that can withstand just about any environment.

Constantly evolving, the medical industry requires OEMs to be forward-thinking in providing solutions that address trends and challenges. One such OEM, Smiths Medical, sought to change the design of its existing pulse oximetry portfolio to include enhanced functionality and improved manufacturability. At the project’s inception, they partnered with the U.S.-based injection molding experts at Kaysun to help refine and ultimately accomplish their goals.

With the freedom to create new features and cost-effectively achieve process efficiencies, it's obvious why many design engineers prefer to use complex injection molding to create plastic parts and components.

What isn’t always clear, however, is the myriad considerations required at the onset of the process. Among them is selecting the appropriate materials to make the actual mold as well as plastic injection molding materials for the part. Here are key points to keep in mind when working through it with an injection molder partner.

Complex injection molding is a viable solution for many projects, but there’s often hesitation in using it because of confusion about which material matches the job. While “thermoplastic” and “thermoset” sound similar and both are appropriate for a wide range of applications, the material properties of these two resin categories and how they behave during processing ultimately reveal the best fit.

Manufacturers of rugged electronic devices (and their end users—for example, the military) count on their “rugged” devices to perform in challenging real-life conditions, and survive being dropped. Therefore impact resistance is a critical feature in product design and starts with material selection.