7 Ways Exceptional Engineering Improves Custom Injection Molding

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3  Essential Focus Areas for No-Fail Injection Molding Quality Control

Manufacturers across industries continue to rely heavily upon custom injection molders to help design, engineer, and produce solutions for complex applications. Not every molder is capable of delivering on these expectations, but those that are will undoubtedly insist upon exceptional injection molding quality control.

 As a trusted partner to OEMs in medical, automotive, industrial, and consumer markets Kaysun is deeply committed to quality and the processes necessary to maintain it. Through strategic implementation of quality assurance initiatives and continuous improvement cycles, our customers are confident in attaining desired results.

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3 Ways Injection Molders Use Design of Experiments to Improve Processes

Custom injection molding is, by nature, highly precise. Part performance and reliability hinge on production processes that ensure accurate, consistent outcomes. Being able to deliver on these nuances is often what sets custom injection molders apart — and generally typifies molders with engineers trained in scientific molding.

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Scientific Molding: 6 Essential Steps for Success [INFOGRAPHIC]

Regardless of application, injection-molded parts and products are expected to perform to stringent quality and regulatory standards.

Ensuring successful outcomes requires application of scientific molding principles by experienced injection molders and trained engineering teams during development and production.

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What is Design of Experiments (DOE) in Scientific Molding?

Each new plastic injection molding project has three inherent goals: performance for the customer; production efficiency for the manufacturer; and, reliability for the end user.

These goals are reasonable. The challenge lies in accomplishing all three within a desired timeframe and budget.

To do so, injection molding plastics engineers turn to Design of Experiments (DOE) to identify flaws during the process design phase that might otherwise derail project success.

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8 Steps to Optimizing the Injection Molding Process

The complexities of engineering an injection molded plastic component or part for a complex application must translate to moldability. If a molder is inexperienced in tool design and process optimization, there’s a good chance 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. 

Learn more about scientific molding in our whitepaper

Let's take a look at the key steps that tool and process engineers take to ensure consistent and repeatable manufacturability of flawless molded parts.

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What is Scientific Molding?

Manufacturers cannot afford to lose any time in getting their products to market. Advances in technology come rapidly, ratcheting up competition for market share. To ensure success, products must be designed and produced with ultimate precision and efficiency. That efficiency depends on eliminating production delays caused by inconsistencies in the manufacturing process.

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The Process of Scientifically Qualifying a Tool

The practice and purpose of qualifying a tool is at the very core of scientific molding. This critical step ensures consistent and repeatable production of flawless molded parts by having engineers push the tool relentlessly under realistic conditions (and sometimes beyond). Their goal is to identify and correct weaknesses before the tool is called into action.

Here’s a look at the basic step-by-step process of scientifically qualifying a tool:

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Scientific Molding in Action [VIDEO]

For manufacturers that produce complex, critical-use plastic parts and components, making sure that exact specifications and dimensions are met during production is crucial to success. Even a miscalculation of just .005 inches can spell disaster for the product and cost thousands to fix.

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Why Scientific Molding Requires Specialized Engineers

Much has been said about the ability of scientific molding to provide optimal control of the injection molding process – and in turn – help manufacturers that use precision-molded parts keep pace with competitors and be first to market. Scientific molding improves part quality by removing guesswork from the injection molding process, but many OEMs still have questions about what really makes it work in the first place. Is it just injection molding with high-tech equipment? The answer is actually the engineers who specialize in it.

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