Designing plastic parts is a complex undertaking involving many factors that meet the needs of the application. "What is the purpose of the part?" "How does it fit with other parts during assembly?" "What loads will it experience during use?" In addition to functional and structural issues, processing issues have a huge impact on the design of injection-molded plastic parts. The way the molten plastic is injected, filled, and cooled within the cavity to form the part largely determines what form the part's properties must take. In addition to being easier to manufacture and assemble, following some basic rules for injection-molded part design generally results in parts that are stronger in use. Dividing parts into basic groups helps you build parts in a logical manner while minimizing molding problems. During part development, always keep in mind how the part is formed and how to minimize stress.
Injection molding is the preferred method of manufacturing plastic parts. Injection molding is used to create many items such as electronic device housings, containers, bottle caps, car interiors, combs, and most other plastic products available today. With the ability to produce multiple parts per cycle using a multi-cavity injection mold, injection molding is ideal for producing large numbers of plastic parts. Some of the advantages of injection molding are high tolerance accuracy, repeatability, a wide range of material options, low labor costs, minimal waste loss and little need to polish parts after molding. Some of the disadvantages of this process are the expensive up-front tooling investment and process constraints.
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