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Injection parts
Injection parts
Injection parts
Injection parts
Injection parts
Injection parts
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Injection parts

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Shortcoming and limit:

  • Uneven contraction leads to deformation
  • Strength loss of the weld seam
  • Differences in environmental tolerance
  • Internal stress issue

 

The main process of injection molding stages:

Mold closing, filling, holding pressure, cooling, mold opening, and demolding.

Stage Description
Casting closure The mold is closed and locked to prevent material from overflowing during injection.
Filling The molten plastic is injected into the mold cavity at high speed until it fills approximately 95% of the cavity.
Pressure retention

(Holding pressure)

 Continuously apply pressure to compensate for shrinkage and ensure the integrity of the product dimensions.
Cooling The process of using a cooling medium to solidify and shape the plastic, which takes the longest time.
Mold opening The mold is opened, ready for the product to be ejected.
Demolding The ejection mechanism pushes the product out, completing the production cycle.

 

The advantage in production and economic:

High efficiency and automation Short forming cycle (usually 30-60 seconds), suitable for large-scale continuous production, low labor cost.
High initial investment The mold design and manufacturing process is lengthy and costly

(ranging from tens of thousands to several hundred thousand yuan),

And it is not suitable for small-batch or single-piece production.
Material utilization rate The waste from gates and channels can be recycled and reused, resulting in low raw material loss. However,

if the proportion of recycled materials is too high, it may affect the performance.
Defect sensitivity Extremely sensitive to process parameters (temperature, pressure, speed)

And mold design (uniform wall thickness, venting, cooling),

Prone to problems such as flash, shrinkage, bubbles, and stress cracking.

 

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Connector Terminals plastic casing and metal

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Extrusion parts

Die casting main feature: Die casting is a metal casting process that involves applying high pressure to molten metal within a mold. The main difference of die casting from other casting methods lies in the high pressure and high speed. Die-cast parts: complex shapes, thin walls, high precision, and a smooth surface with high dimensional consistency. The molds are typically made from stronger alloys, and this process is somewhat similar to injection molding. Which materials are suitable for die casting? Most die-cast parts are quite rare, but it is still feasible. Based on the different metal materials and applications, die castings can be classified as copper die castings, zinc die castings, aluminum die castings, etc. Used for die casting mainly material: zinc, copper, aluminum, magnesium, lead, tin, and lead-tin alloys. The more special die-casting metals: ZAMAK, aluminum-zinc alloys, And the standards of the American Aluminum Association: AA380, AA384, AA386, AA390, and AZ91D magnesium. The advantages and shortcoming of die-casting: Advantages the castings have excellent dimensional accuracy. Shortcoming The main drawback of die casting is its high cost. The equipment for die casting, as well as the molds and related components, are relatively expensive compared to other casting methods. Therefore, it is more economical to produce a large quantity of parts when manufacturing die castings. The processing of die-cast parts mainly steps: Mold preparation, filling, injection, sand removal and post-treatment. Step Specification Mold Preparation During the preparation process, a lubricant needs to be sprayed into the mold cavity. The lubricant not only helps control the temperature of the mold but also facilitates the removal of the castings. Filling and Injection After closing the mold, high pressure is used to inject the molten metal into the mold. The pressure range is approximately between 10 and 175 megapascals. Once the molten metal is fully filled, the pressure will remain constant until the casting solidifies. Sand removal The pusher rod removes all the castings and separates the residues, including the mold opening, risers, gates, and burrs. This process is usually accomplished by pressing the castings through a specially designed finishing mold; Other methods include sawing and grinding. Post-processing During the production process of die-cast parts, problems such as bubbles and burrs may occur, And there may also be residual mold sand and oxide scale. Therefore, after the die-cast parts are manufactured, post-processing work needs to be carried out, including grinding, polishing, spraying, electroplating and other processes. The purpose is to make the surface of the die-cast parts more beautiful, while improving their corrosion resistance and mechanical properties.

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Injection parts

Injection parts