Aluminum Injection Molding in Product Manufacturing
Injection molding is a commonly prevailing technique of manufacturing components for different industries. The process of injection molding helps create components of different shapes and sizes.
The guide below discusses aluminum injection molding and how aluminum injection molds can be used for making components. So, read the guide below.
What is Aluminum Injection Molding?
The aluminum injection molding method helps in producing components using aluminum injection molds; it is used as an alternative to steel injection molding. The applications of aluminum injection molding can be seen in many industries, such as aerospace, automobile, and other industrial processes.
Aluminum molds for injection molding are ideal as they produce complex components very easily. It ensures that the component has a consistent structure and smooth surface.
Features of Aluminum Tooling for Injection Molding
Aluminum molds are made with excellent tooling, which makes them suitable for manufacturing components at a reasonable cost. There are various features of these aluminum molds, and some of these are discussed below:
- Aluminum has a high thermal expansion coefficient, and once it is heated to the appropriate temperature, it cools down easily, speeding up production.
- Aluminum is known for its rigidity and mechanical strength, and hence, can be made with the right tooling methods.
Advantages of Aluminum Injection Molding
Алюминий injection molding offers various advantages, some of which are as follows:
Cost-Efficiency
Aluminum injection molds have lower costs than steel molds. Moreover, the durability of this mold is very commendable, which makes it worth investing in.
Время выполнения
Aluminum molds help create components quickly, but the process of manufacturing using steel injection molds takes more time. The process of designing the mold to manufacture the final product is very extensive. Aluminum injection molds, on the other hand, need only a few days to create components.
Heat Dissipation
Aluminum molds for литьё под давлением offer great heat dissipation, and they cool down very quickly. The manufacturing process is very quick, and it supports having molds for quick and low-volume production.
Good for Low Volumes
When making small batches of parts, aluminum injection molding is a better choice. It offers reliability and has a low production cost, which allows it to easily manufacture affordable components.
Время обработки
The time taken by the process of aluminum injection molding is much less. This is because they dissipate heat quickly, which allows the setting and specification of the components to be specified quickly.
Better Products
One of the major reasons components develop marks and voids is that they have not cooled down or heated uniformly. Since aluminum injection molds have seamless heat dissipation, they cool and heat very quickly and with uniformity. Hence, the number of defects in the parts is reduced.
Easy Repair and Modification
Steel is extremely hard, and the molds of steel, when deformed, require a lot of effort and money for fixation. Aluminum molds, on the other hand, are repairable as they are soft and do not need much effort.
Disadvantages of Aluminum Injection Molding
Aluminum injection molding also has some downsides; these are as follows:
Долговечность
Aluminum injection molds are meant for small-sized component runs. Steel molds are highly durable as they offer corrosion resistance and wear resistance. Hence, aluminum injection molds may offer affordability, but they lack durability.
Complexity
In case any alterations are needed in the layout, the aluminum mold design cannot be modified. However, the steel molds can be modified through heat treatments.
Limited Surface Finish
Aluminum injection molding offers limited surface finishing, whereas steel molds offer lower density, which provides more surface finishing options.
Flash On Part
Flashing is the creation of excessive material on the mold; it develops due to the worn-out cavity, which does not fit perfectly. After thousands of cycles, the aluminum molds wear out.
Fewer Products
An aluminum injection mold is not suitable for high pressure and temperature over a longer span. Hence, they are not suitable when you have to produce high-volume components.
Aluminum Injection Molding vs Steel Injection Molding
When it comes to comparing aluminum injection molding with steel injection molding, the section below can enlighten you.
Гибкость
Steel molds are hard and not flexible. On the other hand, aluminum molds are soft and, therefore, highly flexible, which makes it easier to make adjustments to the prototypes.
Product Design Complexity
Steel molds are suitable for creating components with complex features and for creating precise details. Steel has more strength and can hold its shape well.
Mold Turnaround Time
Aluminum injection molds are manufactured either using EDM or CNC machining. As they are very soft, they do not need further finishing, and hence, they are manufactured in less time. Steel molds, on the other hand, are hard and have some requirements, which makes the process of manufacturing them a longer one.
Mold Robustness
The capability of a mold till the end of its life is known as its robustness. Steel molds are made using harder material, and they also undergo heat treatments. They are durable and rigid compared to aluminum. Aluminum injection molds are soft, and they don't even go through any thermal processing, which makes them wear out quickly.
Handling Aggressive Materials
Some aggressive plastics, like glass-filled nylon and ASA, can impact the molds' lifespan as they require high pressure and temperature when injected. Hence, the mold should be suitable for handling these materials. Steel is suitable for all types of plastics, whereas aluminum molds are not.
Flash Problem
During the injection molding process, the plastic polymer seeps into the mold seams, and this leads to the creation of a flash. They can be removed during post-processing, but the cost of the process increases. These molds are soft and, hence, can deform.
Surface Finish Options
Steel injection molds consist of high-density material, which offers a versatile selection of textures. Whereas, in aluminum, the options of surface finishing are fewer.
Production Time
Production time is the time taken to inspect the plastic, let it solidify, and then remove it from the mold. It all depends on the mold, pressure, and temperature. On one hand, aluminum molds are suitable when they are subjected to regulated pressure. Hence, the production time is shorter.
Aluminum Injection Molding Design
Aluminum mold design plays a vital role in producing the right type of components. Some of the considerations in this context are as follows:
Make Provision for Possible Revisions
At the time of designing an aluminum mold, it is important that the mold be versatile enough to offer revisions. It increases the cost of aluminum injection molds, but when the issue is fixed, it may prove to be cost-effective.
Ensure Uniform Wall Thickness
The wall thickness should be uniform in the aluminum injection mold. The thinner sections tend to cool down quickly compared to the thicker ones, which may lead to inconsistent solidification. Hence, when the walls are even, the inconsistency is not observed in the component.
Use Suitable Alloys
When designing injection molding molds using plastics, adding silicone as an alloy can be a great choice. It offers high specific heat capacity and hence ensures excellent mechanical properties in the component.
Take Note of Part Details
Aluminum injection molds must not have sharp corners; rather, they should have fillets. Sharp corners are made to create shrinkage in the component, which can cause cracks in the component.
Utilize Fillets and Inserts
Inserts and fillets can be added to improve the mold durability where required.
Applications of Aluminum Molds in Different Industries
Aluminum injection molds are widely used in many industries, and some of these are as follows:
Автомобильная промышленность
The automobile industry uses aluminum molds for manufacturing the inner components of a car, like body panels, engine parts, and interior trims. As aluminum is low in weight, it helps to improve feed efficiency in electric vehicles.
Электроника
Electronics industries also depend on aluminum molds for manufacturing electronic components like enclosures, sinks, and circuit boards. Aluminum offers heat dissipation and ensures the manufacture of components that are sensitive.
Медицинская промышленность
The medical sector uses aluminum molds to manufacture various implants, medical tools, and pharmaceutical packaging. It is suitable for components that require biocompatibility.
Заключение
Aluminum injection molding is a versatile process that helps manufacturers produce components for different applications. However, before choosing these molds, it is important to understand everything about them.
The guide above has given you a detailed insight into the overall process. We at DEK can help you have hands-on components manufactured using aluminum injection molding, which are of high quality.
