8 Steps to Optimizing the Injection Molding Process

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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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    5 Reasons Why Medical Device OEMs Need Full Service Injection Molders

    Given the promised speed and generally low price points, commodity injection molders are attractive to OEMs in many industries. However, deals struck with these molders — overseas and domestically — can pose potential problems in communication and quality, among other issues.

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    Scientific Molding: The Key to Quality, Consistency and Profitability

    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.

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    The 6 Essential Steps of Scientific Molding [Infographic]

    As criticality of use ratchets up on injection molded products and devices, plastic components are expected to perform to stringent quality and regulatory standards.

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    Improving Product Development Lead Time

    There isn’t a whole lot that injection molders can do to speed up how long it takes to receive hard tooling. While they wait, however, they can take a number of key steps to streamline the product development process, up to and following the completion of the actual injection mold—saving up to a week or longer in lead time.

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    Preventing Common Manufacturing Defects in Medical Applications

    Manufacturers of medical devices and other medical applications often turn to a complex injection molder for help correcting defects in their engineered plastic components. At Kaysun, we actively seek to prevent defects before they even occur by using a design for manufacturability (DfM) approach that incorporates a comprehensive mold flow analysis and extensive plastics engineering experience to identify any potential issues in the design phase and determine the best strategy to produce defect-free parts.

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