.Clamping force of injection machine minimization. GREAT IDEA!
It can be slightly reduced with multi-drops (from 6 to 8 drops) hot valve gates together with by controlling in a defined sequential time respective gates of opening and closing.
A good idea to reduce cost in the long production run !
Wall Thickness of plastic products design is important.
Non-uniform wall sections can contribute to warpage and stresses in molded parts.
@ Sections which are too thin have a higher chance of breakage in handling, may restrict the flow of material and may trap air causing a defective part.
@ Too heavy a wall thickness, on the other hand, will slow the curing cycle and add to material cost and increase cycle time.
Generally, thinner walls are more feasible with small parts rather than with large ones. The limiting factor in wall thinness is the tendency for the plastic material in thin walls to cool and solidify before the mold is filled.
The shorter the material flow, the thinner the wall can be.
Walls also should be as uniform in thickness as possible to avoid warpage from uneven shrinkage. When changes in wall thickness are unavoidable, the transition should be gradual and not abrupt
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The molded component is twisted, uneven, or bent shape where one was not intended. Warping is usually caused by non-uniform cooling of the mold material. Different cooling rates in different parts of the mold cause the plastic to cool differently, thus creating internal stresses. These stresses, when released, lead to warping.
@Ensure that the cooling time is sufficiently long and that it is slow enough to avoid the development of residual stresses being locked into the part.
@Design the mold with uniform wall thickness and so that the plastic flows in a single direction.
@Select plastic materials that are less likely to shrink and deform. Semi-crystalline materials are generally more prone to warping.
Design for manufacturability is also known as design for manufacturing or DFM in short.
In the industry of plastic injection molding. DFM is more often like”design for moldability“, as mold makers focus on the feasibility of injection molding process. A report (normally in PPT) on DFM to show customers how to optimize part design, our molding solution and potentially problem areas of your plastic parts.
It is free of charge.
Plastic Part Deformation in control from START in plastic part design !?
Plastic design, mold design, plastic materials selection and injection parameters are the 4 keys in affecting final plastic part deformation. The plastic part design is dominated the others.
With uneven wall thickness and differential shrinkage at different locations:
- mold design and raw plastic materials will make up a little effect,
- injection molding parameters setting will then be more demanding for reducing deformation of parts under constant part weight and tool gating size by means of
@ lower mold temperature
@ longer cooling time
@ lower holding pressure
Working in plastic injection mold making and molding International sales and marketing director.