Increasing the clamp force to 5-7 tons per square inch is a must when you're packing thin walls. You can also reduce flexure by using extra-heavy platens. Another effective method is closed-loop control of the injection speed and transfer pressure. Ultimately, the process should take much less time than a thick-walled mold. In addition, the thinner-walled product will be lighter and have a much smaller volume than a thick-walled product.
Thick-wall injection molding reduces cycle times
Injection molding machines that offer thin-wall capabilities are in high demand. This technology enables molders to produce parts with walls as thin as one millimeter. For large automotive parts, this can be as thin as two millimeters. This technology requires different processing conditions, including higher pressures, shorter cooling times, and modifications to part-ejection and gating arrangements. This requires specific machinery and molds.
Thin-wall injection molding machines are equipped with accumulators to drive the injection and clamping cycles. Some machines are electric or hybrid electric/hydraulic, and offer a high-speed clamping force.
Reduces weight
Using a process that reduces the thickness of thin wall injection molding components can increase the strength and reduce the weight of a product. The process also uses less plastic and reduces CO2 emissions. It is also possible to use more environmentally friendly plastics such as biodegradable resins and biomass polyethylene. The weight reduction is possible without sacrificing strength.
Using a process that reduces the mass of a part will help reduce the weight of the finished part and reduce cost and cycle time. However, when using this process, certain parameters are important, and the right equipment is essential to ensure the part is lightweight.
Reduces size
The process of thin wall injection molding is a critical step in the production of lightweight, smaller automotive components. This process is best suited for parts with walls of 1 to 2 mm. This type of molding requires a different processing approach than conventional molding. It requires higher pressures, faster cooling times, and a modified gate and ejection system. Changes to the mold design have also been made. The mold is now equipped with accumulators on clamp units, servo valves to control the injection and decompression speeds, and closed-loop control for temperature.
During the production process, thin-walled parts must be uniform in thickness to prevent shrinkage. Parts that need to be durable may also be molded with a ribbed design. These ribs can reduce warping. Besides being more cost-effective, ribs can help minimize the overall thickness of parts. They also cool more quickly than thicker parts and require less material.
Reduces cost
When it comes to the process of thin wall injection molding, it's important to design your parts for efficiency. This means considering the amount of material that needs to be molded, as well as reducing errors. For example, round corners are important to prevent air bubbles, and maintaining a sufficient thickness of the walls will reduce the chance of warping. Ribs are also a cost-effective way to increase the strength of your parts without adding extra material to the mold.
Aside from saving material, thin wall injection molding can also reduce costs, cycle times, and part weight. To make this possible, you will need a high-speed injection molding machine that can withstand high pressures and clamp tonnages. These machines are expensive, and you'll need to invest in a high-quality mold. Additionally, you'll need an appropriate cooling system for your molds. These features will increase productivity and reduce the cost of thin wall injection molding.
High quality 2 cavities plastic thin wall bucket mould1. Bucket dimension is φ100x90mm.2. Bucket weight is 12g.3. Wall thickness is 0.6mm.Technical Points of thin wall mould:
Recommended thin wall bucket mould steel material: S136 or H13 steel after vacuum hardening, hardness can reach HRC 45-52.
A good cooling system is very important for thin wall mould, usually we will add more water channel and insert beryllium copper to help mould cooling.
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