3 Major Functional Units: Injection, Mold, Clamping

It is a manufacturing technique for making parts

from thermoplastic and thermoset materials
In contrast to the extrusion (which makes
continuous parts of constant cross section),
injection molding make discrete parts (with
complex and variable cross section)
Molten plastic is injected at high pressure into a
mold, which is the inverse of the desired shape.
The mold is made from metal, usually either
steel or aluminium
Widely used for manufacturing a variety of
parts, from the smallest component to entire
body panels of cars
Purpose: to liquify the
plastic materials and
then inject the liquid
into mold
Resin is introduced
through hopper
Some machines can
have several hoppers
(to fed filler, colorants,
other additives)-
Injection molding act as
mixer
However, due to limited
size of barrel, mixing
capability is poor
From hopper hole (feed throat)
Barrel made of heavy steel cylinder to
withstand the pressure and temperature
involved in melting the resin
2 types of system used in injection molding;
Reciprocating screw- similar to extruder screw
but with unique reciprocating action
Ram injector
 Design of screw- similar to an extrusion screw
3 sections:
Feed section- to advance the resin
Compression section- to melt the resin
Metering section- to homogenize the resin and pump it
forward
The screw of injection molding machine is shorter
than extruder, L/D ratios are 12:1 and 20:1
Low L/D ratios suggest the mixing is less efficient
in the injection molding machine
The compression ratio (diameter of root at feed
zone to the diameter of root at metering zone)
often in the range of 2:1 and 5:1
Low compression ratio means less mechanical
action is added during melting process
Important measure of the size of an injection
molding is weight of resin that can be
injected, called shot size
Typical shot size range from 20g to 20 kg
Since shot size depends on the density of the
plastic, PS has been chosed as the standard
for rating the machine
 Resin is melt by mechanical shear and thermal
energy from heaters
The molten resin is conveyed to a space at the
end of the screw- collects in a pool
Here, the mold is closed
 The entire screw move forward and pushes the
molten resin out through the end of barrel
To ensure the resin does not flow backward, a
check valve or nonreturn valve is attached to the
end of screw
Normally the screw will stay in the forward
position, until resin began to harden in the mold
 Retraction of the screw, create space at the end of
the screw
Cooling of the part in the mold, until it can be
removed
While the part is cooling, the screw turns and melts
additional resin
Advantages
More uniform melting
Improved mixing or additives and dispersion
throughout the resin
Lower injection pressure
Fewer stresses in the part
Faster total cycle
 In this type of injection molding, the resin is fed
from a hopper into the barrel, and heated through
thermal energy from the heaters
The molten resin is collect in a pool in a barrel
celled injection chamber
The molten resin is then push forward by the
action of plunger (ram or piston)
To five better mixing, the molten resin is pushed
past a torpedo/spreader, impart shear to the melt
 Prior to the injection of the molten plastic into the mold,
the two halves of the mold must first be securely closed by
the clamping unit. When the mold is attached to the
injection molding machine, each half is fixed to a large
plate, called a platen. The front half of the mold, called the
mold cavity, is mounted to a stationary platen and aligns
with the nozzle of the injection unit. The rear half of the
mold, called the mold core, is mounted to a movable
platen, which slides along the tie bars. The hydraulically
powered clamping motor actuates clamping bars that push
the moveable platen towards the stationary platen and
exert sufficient force to keep the mold securely closed
while the material is injected and subsequently cools. After
the required cooling time, the mold is then opened by the
clamping motor. An ejection system, which is attached to
the rear half of the mold, is actuated by the ejector bar and
pushes the solidified part out of the open cavity.
Obviously, the mold must be cooled in order for the
production to take place. Because of the heat capacity,
inexpensiveness, and availability of water, water is used
as the primary cooling agent. To cool the mold, water
can be channeled through the mold to account for quick
cooling times. Usually a colder mold is more efficient
because this allows for faster cycle times. However, this
is not always true because crystalline materials require
the opposite: a warmer mold and lengthier cycle time.
The key to success in injection molding are
to have:

Proper machine for good melting and injecting of

the resin
The proper resin to appropriate part
performance
A good mold for part definition and removal
Proper operation for efficient molding cycle
(mold cycle depends on the design of the mold
and manufacturing parameters)
The most commonly used thermoplastic
materials are:
Polystyrene (low-cost, lacking the strength and
longevity of other materials)
ABS or acrylonitrile butadiene styrene (a co-
polymer or mixture of compounds used for
everything from Lego parts to electronics
housings)
Nylon (chemically resistant, heat-resistant, tough
and flexible - used for combs)
Polypropylene (tough and flexible - used for
containers
PVC (more common in extrusions as used for
pipes, window frames, or as the insulation on
wiring where it is rendered flexible by the
inclusion of a high proportion of plasticiser).
Aerospace components
Automotive components
Avionics components
Cable assemblies
Computer electronics
Electronics components
Encapsulations
New product design &development
R&D labs Test specimens
Engineering prototypes
Geophysics
Instrumentation
Marketing samples
Material quality testing
Medical & dental products
Medical laboratories
Model shops, toys, hobby
Injection molding is one of the most important
processes for plastics and it has a very wide list
of kinds of products it can produce, which makes
it very versatile.