What's thin-wall injection moulding?
Thin wall moulding is a specialized form of conventional injection moulding that focuses on mass-producing plastic parts that are thin and light, without structural compromise, in order to achieve material cost savings and shorter cycle times. Faster cycle times improve productivity and lead to lower costs per part.
The definition of a thin wall is really about the size of the part compared to its wall thickness. For any particular plastic part, as the wall thickness is reduced, the harder it is to manufacture using the injection moulding process. The size of a part puts a limit on how thin the wall thickness can be. For packaging containers, a thin wall means wall thicknesses that are less than 0.025 inches (0.62mm) with a flow length to wall thickness ratio greater than 200.
Why the thin-wall mould get more popular?
Speed is one of the key factors for successful thin-walled injection moulding. Fast mould filling and high pressure can inject molten thermoplastic material into the mould cavity at high speed, thereby preventing the gate from being cold and solid. If a full injection moulding cycle is completed in two seconds and the wall thickness is designed to be reduced by 25%, the filling time can be reduced by 50%, just one second.
One of the advantages of thin-walled injection is that when the wall thickness is reduced, there is less material to be cooled. As the wall thickness decreases, the moulding cycle can be reduced so much.
The reasonable setting of the melt conveying device makes the hot runner and runner system not obstruct the shortening of the moulding cycle. The use of a hot runner helps to shorten the moulding cycle to a minimum.