Low-Volume Injection Molding: Complete Guide
Injection molding is usually used for mass-volume production, but it can also be opted to create low-volume components and make functional prototypes in a cost-efficient manner.
The guide below can offer you useful information about low-volume injection molding, its benefits, and more. So, let's read.
How Low-Volume Plastic Injection Molding Works
The process of low-volume plastic injection molding has the following steps, and these are discussed in detail.
Creating Mold Design
The first stage is designing the mold in a digital software. You will get a digital design that will be printed with a 3D printer and then will be ready to use.
3D Printing Mold
A 3D printing mold material is selected first to create the mold that will be used for injection molding. The mold material selection should be based on thermal resistance, strength, and stiffness.
The printer is then instructed to print the mold layer by layer using its additive manufacturing process.
Assembling the Mold
Mold that you have designed and printed must be assessed for any further finishing process so that it meets the dimensions of the component. The stability of the component will highly depend on the perfection of mold.
Prepare Injection Molding Material
The plastic pellets are melted so that they can be used for the injection molding process. There is a wide range of thermoplastics that are compatible with 3D printed molds, including ABS, POM, TPU, PP, PE, etc.
Injection Process
The injection stage is where the molten thermoplastic is injected into the 3D printed mold to take the shape of the required component. During the process, pressure and temperature must have stability so that results are optimal.
Cooling
The injection molded component is left to rest and cool down and then it solidifies. The process of cooling can be sped up using compressed air which allows cooling of the mold quicker and even the process of solidification.
Demolding
Once the component has solidified you have to demold it, the process of demolding can either be manual or automated. The process of automatic demolding uses ejector pins which releases the component from the mold.
Benefits of Low-Volume Injection Molding
The process of low-volume injection molding has some benefits, and these are as follows:
Affordable Prototypes
Low-volume injection molding allows prototypes to be produced in an effective way. Hence, the need to produce a high volume for testing purposes is eliminated, and companies testing new parts can make the best use of it.
Quick Market Entry
The process of low volume injection molding takes into account the quick flow of components in the market.
Hence, if you are experimenting with new items and want them to be released quickly in the market, the process of injection molding is quite a suitable one.
Flexible to Modifications
The process of low-volume injection molding offers flexibility when any modifications in the design are needed. The process allows significant changes to be made with increasing cost into the design so that the final component meets your requirements.
Prevents Risk of Large Volume Production
Low volume injection molding gives an opportunity to test the components produced before large volume production is done.
It allows floating a small batch to be tested. After the validations, any required adjustments are made. It helps to reduce operational and financial risks which are attached to high volume production.
Choose the Right Material for Your Injection Molded Part
The process of low-volume plastic injection molding involves a wide range of materials, and these are as follows:
- Acetal: It is a highly stable material when subjected to high temperatures and offers high rigidity, chemical resistance and low water absorption.
- Acrílico: Acrylic is a UV-resistant and strong material that is chosen for its optical clarity and lightweight.
- ABS: It is a strength-oriented and impact-resistant material and works well even at low temperatures.
- Nylon: It offs heat, abrasion, and fatigue resistance to the injection molded components.
- PBT: Known for its creep resistance, it is used in components that have thinner cross-sections.
- Polycarbonate: It is lightweight and strong, offers stable properties and can stay firm over a wide range of temperatures.
When to Use Low-Volume Injection Molding
Low-volume injection molding can be used in two cases, and these are as follows:
Creación rápida de prototipos
Rapid prototyping is a process which can help companies turn their ideas into a physical prototype which can be assessed and tested for its functionality and design.
Rapid prototyping is mostly opted with 3D printing. When 3D printing and injection molding combine, manufacturers are able to produce the prototypes faster and hence the development process of components progresses.
Short-Run Production
Short-run injection molding also allows manufacturers to create a small batch of production for the components so that these products can be tested in the market at a lower scale before floating them at a larger one.
In case there is any type of improvement needed, it can be retried without wasting time, resources and money.
Applications of Low Volume Plastic Molding
The low volume plastic molding is used in various applications, and some of these are given below:
Industria médica
The medical industry requires customized components that are manufactured patient-specific and these are required in low quantities. Low-volume injection molding proves to be the best option for such medical components.
Industria del automóvil
In the automobile sector, some vehicles are limited edition, and they might need replacement parts, which makes low-volume injection molding a better choice. The required number of replacement parts can be obtained of the required quality.
Industria electrónica
Technology is evolving very quickly and electronics go through several transitions and need modifications in designs before they are finalized. Low volume injection molding can facilitate this process quite effectively.
Industria aeroespacial
Aerospace industry requires components that are precise and high quality. Low-volume injection molding ensures that the components produced in less quantity have the desired accuracy and precision.
Alternatives to Low-Volume Plastic Injection Molding
The alternatives to low-volume plastic injection molding are as follows:
Impresión 3D
The process of 3D printing is a cutting-edge approach that allows the manufacturing of high-quality components in small batches.
These 3D components are manufactured at a low cost and in less time. For further finishing, they can easily be rubbed with sandpaper or painted.
Mecanizado CNC
CNC machining is a very common method for manufacturing components. It's a versatile process and can be opted with different materials.
It allows manufacturing patterns, dies and molds which can further be used in different types of manufacturing processes.
Urethane Casting
Urethane casting is also an alternative to injection molding. It is a very low cost method which requires a pattern to be manufactured through CNC machining and 3D printing and after that, urethane casting is done.
Thermoforming
Thermoforming is a very effective method that allows molds to be created to hold the sheet of plastic, which is very thin during the process of heating.
As the plastic is heated, it can be shaped by pressure and force. The plastic sheet will take the shape of the mold, and if there is any excessive plastic, it can be cut down.
On-Demand Manufacturing in Injection Molding with DEK
Low low-volume injection molding process can be carried out with custom designs, and if you are looking forward to having these customized low-volume components manufactured through plastic injection molding, you can get in touch with us at DEK.
We offer high-quality components manufactured in low volume with low costs.
Conclusión
The guide gives you a very detailed look at the low-volume injection molding process and how it benefits.
You must have learned about the process of manufacturing molds and the relevant materials for this process. You may opt for low production of injection molded components for your upcoming projects.
