STRUCTURAL FOAM MOLDS Structural Foam Injection Moulding

 STRUCTURAL FOAM MOLDS      Structural Foam Injection Moulding    Structrual Foam Molds for Industrial Products

 

Tool features:

thick wall thickness product.

Part function: Structrual Foam molds for industrial products.

Part material: ABS+foam agent

 

The Structural Foam Molding Process

The process of molding parts from structural foam is very similar to the traditional method of reaction injection molding. Two components, for example polyol and isocyanate (which are combined in order to create polyurethane) are stored in liquid form in separate containers. They are mixed together to form a resin which is injected into a pre-prepared mold and cures via the means of a chemical reaction.

 

However, there is one important difference necessary for the creation of structural foam rather than a solid polymer. In addition to the polyol and isocyanate, an inert gas or chemical blowing agent is added to the mix during the injection process. This changes the nature of the chemical reaction which ultimately occurs.

 

Less polyol and isocyanate are used than in standard solid polyurethane reaction injection molding, so that the resin does not completely fill the mold. Instead, the gas or blowing agent is activated by the reaction between the two components. It expands, filling the empty space of the mold with foam. This creates the “honeycomb” texture for which the interior core of structural foam is known. Surface cells collapse when they come in contact with the walls of the mold, resulting in the creation of the solid skin which surrounds the outside of the material.

 

Structural Foam Molding Benefits

There are numerous benefits associated with using the foam injection molding process, these advantages include:

Utilizes less energy – This process uses less energy per pound of plastic and less raw material within the finished product.

Reduced molding costs – Part weights can be reduced by 15%, which results in lower material costs, without affecting structural integrity.

Larger product design capabilities – Smaller parts can be combined, with contrasting functions, into one part to decrease cost and increase efficiency.

Conserves raw materials – Low-pressure molding consumes less raw material than comparable methods.

Family molds run together – Due to large platen sizes, family molds can run together to create complete assemblies without the wait.

Increased dimensional stability – Low-pressure injection combined with expanding nitrogen gas results in the creation of parts with less internal stress. As a result, the foam injection molding product remains straighter and has increased dimensional stability when subjected to temperature changes and long-term weather exposure.

Increased strength to weight performance – The structural nature of the molten resin core allows for increased performance per pound of plastic.

Material variety – Lomont’s low-cost molding capabilities allow for numerous types of resins to be used.

Efficient and cost-effective – Our structural molding process offers an efficient and cost-effective way to produce advanced quality, easily repeatable parts, for your next foam injection molding project.

 

WIT Mold is a professional mold manufacturer in China, with 10+ years rich experience in mold making, specializing in making different types of injection molds widely used in automobiles, household electrical appliances, telephone housing molds etc.

 

https://witmold.com/product-item/stuctural-foal-molds/

 

GAS ASSIST MOLDS Gas Assist Molds Maker

 GAS ASSIST MOLDS    Gas Assist Molds Maker     Gas Assisted Injection Moulding     China Mold

 

Basic concept

Plastic forming process where a plastic melt is injected into a mold and where also a gas injected for pushing the melt towards the mold internal walls where the melt is solidified.

 

Tool features:

1. High requirements for part surface treatment.

2. thick wall thickness product.

Part function: Handle for Suitcase

Part Size: 162X151X16mm

Tool Size: 350X550X297mm

Part material: PP

Insert steel: ORVAR SUPREME 8407 (H13 Equivalent)

Cav. QTY: 1X2

 

Gas Assist Molds Advantages

Less plastic material needed (material savings)

Reduced part weight (in some cases up to 40%)

Decreased cycle time

Increased part strength and rigidity

Reduced warpage and distortion

Improved part appearance (eliminates sink marks and surface blemishes)

Reinforces ribbed parts

Increased design options for complex parts, reducing multiple part assemblies, and metal to plastic conversions

Enables use of smaller plastic injection molding presses

In gas assist plastic injection molding, the pressurized gas follows the path of least resistance and displaces the plastic material in the thicker areas of the part, leaving hollow sections for reduced material use and part weight, yet not compromising part appearance or functional performance.

 

With gas assist molding, localized gas pressure within the mold results in better packing of the plastic which reduces warpage, shrinking, surface blemishes, sink marks and internal stress. Gas assist injection molded plastics generally make for stronger and more aesthetically pleasing parts.

 

Gas assist molding is used to reinforce ribbed parts and provides more design freedom for complex parts, reducing multiple part assemblies and metal to plastic conversions.

 

The need for less plastic material and the consistent pressurization within the mold also enable gas assist injection molded plastics to cool faster, reducing cycle times and increasing plastic injection molding machine output – saving time and cost!

 

In gas assist plastic injection molding, the internal pressure provided by the nitrogen gas enables lowering the outer force needed to hold part shape, so large plastic parts can be produced with less tonnage on smaller plastic injection molding machines.

 

Disadvantages

This molding technique is very difficult to apply for multi-cavity mold, especially if the cavity sizes are dissimilar. Clear or transparent plastic materials are an inappropriate option for this technique as cosmetic-appearance can deteriorate

 

Applications

Some applications benefiting from gas assist plastic injection molding include:

 

Appliance handles

Medical equipment housings

Interior and exterior automotive handles

Large covers and panels for office equipment

Lawn mower handles

Steering wheels

Basketball backboard frames

Long tubular shapes, such as shovel handles

Large parts with ribs and bosses

 

WIT Mold supply all kinds of molds, such as conventional plastic molds, precision injection molding, unscrewing molds, two shot injection molds etc., and are mainly exported to North America, Europe and other parts of the world.

 

https://witmold.com/product-item/gas-assist-molds-2/

 

64 cavities mould for plastic cap(PP) High cavitation injection molds

64 cavities mould for plastic cap(PP)     High cavitation injection molds      High Cavitation Molds Company

 

HIGH CAVITATION MOLDS

Tool features:

1. Internal thread mould/ internal unscrewing mould/ Threaded plastic injection mould.

Part function: plastic bottle caps

Part material: PP

Cavity: 64 cavities

 

High Cavitation Injection Molding presents its own unique set of challenges within the subset of the industry.  Balance plays a huge role. Balancing in the hot runner manifold obviously must be done upfront with mold flow analysis data. Balancing in the hot runner tools takes a little more finesse.  Although resin plays a huge role in material flow, heater and water flow control is also a contributing factor. Any time cavity pressure control can be used, you’re ahead of the curve. Post gate cavity transducers can contribute to a huge cost avoidance early in the program.

Once you get into high cavitation molding, the sky is the limit.  You could be dealing with stack tools, cube molds, and so on.

 

Balance always plays a role no matter what, especially when it’s high volume and low margin.  Every cycle counts and machine downtime and scrap are blows to the potential revenue.

 

Many times it’s easy for cavities to be lost during the molding process.  This is often from gate issues, improper venting causing burns, flashing issues, etc.  Once a gate is blocked off the mold can start to become unbalanced.  The more cavities are down, the tougher it is to keep a balance on the tool.  The tooling team has to be involved once a process gets to this point.  

 

WIT Mold is a professional mold manufacturer in China, with 10+ years rich experience in mold making, specializing in making different types of injection molds widely used in automobiles, household electrical appliances, telephone housing molds etc.

 

https://witmold.com/product-item/high-cavitation-molds/

TWO SHOT INJECTION MOLDS Two Shot Mold

 TWO SHOT INJECTION MOLDS   Two Shot Mold    Two Shot Injection Molds    Two Shot Injection Molds China

 

Double Injection, sometimes known as 2 material 2 shot molding or 2K molding, is an innovative manufacturing process used to produce complicated molded parts from two different materials. Through a highly specialized and automated process we carefully control the injection of multiple materials, including two different kinds of resin, into a single, multi-chambered mold.

 

Double Injection in performed on one machine that is programmed to perform two injections in one cycle. In the first cycle, a nozzle injects plastic into a mold. The mold is then automatically rotated and a different type of plastic is injected into the mold from a second nozzle.

 

Double Injection Molding optimizes co-polymerization of hard and soft materials to create powerful molecular bond. The result is a single part with production and feature advantages. It can be used for a variety of product designs across all industries. It also allows for molding using clear plastics, colored graphics and stylish finishes which improves your product functionality and marketplace value.

 

WIT MOLD features:

1. bi-injection mold/ 2 shot mold/2k injection moulding technology/ two-color mould.

2.Complicated structural part.

3. High polishing.

Part function: Cup holder for Audi automobile

Part material: PC+TPE

Features:Two-shot injection moulding can be

used to bond a part of hard material with

another soft material.

 

WIT MOLD Double Injection advantages include:

Lower unit cost

Improved part integrity

Multi-material efficiency

Higher-quality plastic part fabrication

Reduced handling and secondary assembly

Reduces cost and waste associated with assembly defects

Enhanced tactile and cosmetic product features

 

WIT Mold supply all kinds of molds, such as conventional plastic molds, precision injection molding, unscrewing molds, two shot injection molds etc., and are mainly exported to North America, Europe and other parts of the world.

 

Our website:witmold.com

 

https://witmold.com/product-item/two-shot-injection-molds-5/