Shovel dimension: 250*90mm
Rake dimension: 230*90mm
Raw material: PP, food-grade
Mould steel: P20
Mould base: 60#
Nos of cavity: 2+2
Injection system: cold runner
Mould size: 675*400*400mm
Suitable machine: MA900 or MA1600
SWY MOULD is a fully equipped mould making factory, with all sets of process machines, injection machines, and testing equipment. Our experienced engineer team, skilled toolmakers, and advanced equipment offered high-quality service, such as solving design problems, reducing production cost, fast delivery, etc.
As many manufacturers are discovering, plastic resins are a high-quality, cost-effective alternative to metal and other cost-prohibitive or technically challenging materials. Our team of experienced designers, engineers, and craftsmen have the skills and knowledge to deliver the best possible parts at the best possible price using a variety of technically advanced materials. We can help you determine the most appropriate material for your new products.
Our commitment to exceptional customer service underlies everything we do, giving our customers a seamless experience from concept to delivery. SWY is prepared to successfully complete your next project.
Major advantages of plastic injection moulding
1. High efficiency-fast production
Once the injection molds have been designed to the customer’s specifications and the presses pre-programmed, the actual molding process is very quick compared to other methods of molding, and the high production output rate makes it even more efficient and cost-effective. Speed depends on the complexity and size of the mold but only about 15-120 seconds pass between each cycle time.
2. Detailed features and complex geometry
The injection molds are subjected to extremely high pressure. As a result, the plastic within the molds is pressed harder against the mold compared to any other molding process. Due to this excessively high pressure, it is possible to add a large number of details to the design of the part.
With the right design, parts can be made consistently and with quality. Without a good design, costly processing mistakes can be made
3. Enhanced strength
Strength is one of the key factors that need to be determined when designing a plastic injection molded part.
In plastic injection molding, it is possible to use fillers in the injection molds. This filler reduces the density of the plastic while it is molded and also helps in adding greater strength to the part after it has been molded.
4. Flexibility- material and color
One of the major advantages of using plastic injection molding for manufacturing parts is the ability to use different types and colors of plastic simultaneously. This can be done with the help of co-injection molding. Due to the wide variety of both, the possibilities are almost endless.
5. Save manufacturing costs
Labor costs are typically relatively low in plastic injection molding, in comparison with other types of molding. The ability to produce the parts at a very high level with a high output rate helps with its cost efficiency and effectiveness.
Plastic injection molding is an automated process. Automation helps to reduce manufacturing costs, as the overheads are significantly reduced.
Injection mould production process
1. Process analysis of plastic products.
Before designing the mould, the designer should fully analyze and study whether the plastic product conforms to the principle of injection molding, and needs to negotiate carefully with the product designer, and a consensus has been reached. This includes necessary discussions on the geometric shape, dimensional accuracy, and appearance requirements of the product, and trying to avoid unnecessary complexity in mould manufacturing.
2. The mold structure design.
A set of high-quality moulds not only requires good processing equipment and skilled mould manufacturing workers but also a very important factor is to have good mould design, especially for complex moulds, the quality of mould design accounts for 80% of the quality of the mould. %above. An excellent mould design is: on the premise of meeting the requirements of customers, the processing cost is low, the processing difficulty is small, and the processing time is short.
To do this, it is necessary not only to fully digest the requirements of the guests but also to have an understanding of the injection molding machine, mould structure, processing technology, and the processing capacity of the mould factory itself. Therefore, to improve the level of mould design, the following points should be done:
* Understand every detail in each mould design, and understand the purpose of each part in the mould.
* Refer to the previous similar designs when designing, understand the situation in its mould processing and product production, and learn from the experience and lessons.
* Learn more about the working process of the injection molding machine to deepen the relationship between the mould and the injection molding machine.
* Go to the factory to understand the process of processed products, and recognize the characteristics and limitations of each type of processing.
* Understand the test results and mold modification of the mould designed by yourself, and learn from it.
* Try to use the more successful mold structure in the design.
* Learn more about the influence of water in the mold on the product.
* Study some special mold structures and understand the latest mold technology.
3. Determine the mould material and select standard parts.
In the selection of mould materials, in addition to considering the accuracy and quality of the product, it is also necessary to give the correct choice in combination with the actual ability of the mould factory's processing and heat treatment. In addition, in order to shorten the manufacturing cycle, the existing standard parts are used as much as possible.
4. Parts processing and mould assembly.
In addition to giving the best structure and reasonable tolerance in the design, the precision of the mould is very important for the machining of parts and the assembly of the mould. Therefore, the choice of machining accuracy and machining method occupies an absolutely dominant position in mould manufacturing.
The dimensional error of molded products is mainly composed of the following parts:
* The manufacturing error of the mould is about 1/3
* The error caused by mould wear is about 1/6
* The error caused by uneven shrinkage of the molded part is about 1/3
* The error caused by the inconsistency between the scheduled shrinkage and the actual shrinkage is about 1/6
Therefore, in order to reduce the mould manufacturing error, the machining accuracy should be improved first. With the use of CNC machine tools, this problem has been well controlled. In addition, in order to prevent errors caused by mold wear and deformation, quenching should be used for key parts such as cavities and cores in moulds with high machining accuracy requirements and large product output. In medium and large moulds, in order to save materials and facilitate processing and heat treatment, the mosaic structure should be used as much as possible in mould design.
In order to solve the error caused by the uneven shrinkage of the molded parts and the inconsistency between the predetermined shrinkage and the actual shrinkage, 1/3 of the product tolerance is generally selected in mould manufacturing as the manufacturing tolerance of the mould. Large room for adjustment to account for errors caused by the molding process.
5. Test mode.
A set of molds is only 70% to 80% of the entire manufacturing process from the start of design to the completion of assembly. For the error caused by the inconsistency between the predetermined shrinkage and the actual shrinkage, whether the demolding is successful or not, how is the cooling effect, especially the influence of the size, position, and shape of the gate on the accuracy and appearance of the product, it must be tested by mould trial. Therefore, mold tryout is an indispensable step to check whether the mould is qualified or not and to choose the best molding process.