Part Material: PC
Mould Steel: S136
Mould Base: LKM
Cavity Number: 1
Melting Point: 260 – 340 degrees
Mould Temperature: 70 – 120 degrees Celsius
Plastic Injection Molding Pressure: keep the pressure as high as possible, to enable fast molding
Plastic Injection Molding Speed: adopt slow plastic injection molding speeds when small-sized or edge gate is used; adopt higher speeds for the rest gate types
Polycarbonates (PC) is an amorphous thermoplastic. These polymers allow transmission of light; like as in a glass. An important feature is that they can be heated to their melting point, cooled, and heated again without degrading themselves. As PC can liquify, you can undertake injection molding. They are resistant to heat and can be used with flame retardant materials also, the molding parts made in Polycarbonate which we called Polycarbonate injection molding.
Uses of Polycarbonate (PC)
They are an absolute necessity when there is you need to impact resistance and transparency. PC (Polycarbonate) can be used across multiple industries. They are primarily used in different medical devices, digital compact disks, protective gear, eyewear, and much more. It is finding use with security agencies for mob control and finds its way into materials for protective visors and riot shields. PC (Polycarbonate) finds use in your car. Being flexible and heat resistant, PC (Polycarbonate) is located in the internal focal points; radiator flame broils, entryway handles, and front light bezels. Polycarbonate is also used in making nurseries and greenhouses. It is UV resistant, allowing in the sun rays but not allowing the UV rays.
What is PC injection molding?
It is a manufacturing process to produce objects by inserting the molten PC (Polycarbonate) into a mould. Usually, the melt temperature for PC material is between 270-320 degrees Celsius. It may decompose at high temperatures and cause defects like bubbles, black spots, etc. Typically, the injection pressure is controlled between 80 and 120 MPa.
Benefits of PC injection molding
The benefits arise from the type of material that is molded to give the end-product. The benefits of polyurethane molding come from the characteristics of polycarbonates that are used in the process:
1. Easy to make.
PC is lightweight but durable making installation so easy. You can even cut them with scissors, if necessary.
You can be creative with the structures. You can easily shape igloos out of it. Go ahead with those fancy shapes in your mind.
3. Resistant to impact.
You are worried about breakage.
The material can resist rain, hail, and storms. It is resistant to flames and does not emit toxic gases when on fire.
4. Protects against harmful UV.
They keep out the harmful radiation. They do not let the harmful rays into the glasshouses that are made of these materials.
5. Meager costs.
These materials are easy to carry and handle. You do not have to bear high handling costs and labor.
Two facts that affect the quality of PC molding product
In the PC plastic injection molding process, the choice of moisture control and molding conditions are the two most important factors that affect the quality of the molded product, as respectively described below:
1. Moisture control
PC plastics are prone to hydrolysis, bond breaking, molecular weight reduction, and physical strength decrease even when they encounter a very low level of moisture. Therefore, before the plastic injection molding process, the moisture content of PC should be strictly controlled below 0.02% to avoid a decrease in the mechanical strength of the molded product or an abnormal appearance, e.g., bubbles, crazes, or the like on the surface. In order to avoid abnormalities caused by moisture, the PC should be dried in a hot air dryer for 3 to 5 hours before processing with the temperature set at 120°C, or remove the moisture by a dehumidifier, but the dehumidified air should have a dew point of -30°C at the entrance to the funnel.
2. Injection molding
To satisfy the needs of various injection molding processes, PC materials are designed with different melt flow indexes. Generally speaking, a melt flow index of 5 to 25 g/10min is suitable for the plastic injection molding process. However, the optimal processing conditions vary greatly depending on the type of the injection molding machine, the shape of the molded product, and the specifications of the PC material, so adjustments should be made according to the actual situation.