Injection molding is among the most-used manufacturing processes, and it’s ideal for mass production. Manufacturers only need to create an injection mold, and after that, they can print thousands of identical parts. With a higher production volume, this method reduces the price per part.
There are many misconceptions about the injection molding process that confuse beginners. So, let’s dive into some common myths that you need to know.
All Shapes Are Moldable
When we think of robust manufacturing, it’s easy to believe that any geometry is possible to design and build. But, it’s not possible to mold any and every shape because the material is moldable to a great degree. If the moldability is sub-par or if there is an error, you will encounter several production problems. When there are issues in mold making, it substantially impacts the final product.
The image is used for illustration purposes. Karv Automation is not the owner or creator of the image. (Image Source: Mastars on Unsplash)
It’s untrue that plastics of any shape or geometry are easy to mold. Engineers need to modify a majority of the designs if they are not malleable at least 90%. For molding a geometry with perfection, the balance between heat exchange and melt flow has to be correct.
Parts Can Only Be Personalized Post-Production
There is a common misconception that the parts produced by injection molding can’t be both functional and aesthetic. This confusion in injection molding comes as people believe plastic injection molding can only retain the base color of the resin. However, it’s a myth, and you can personalize the product while producing it with higher efficiency.
You can modify several aspects like finishings, texture, and color and print the desirable object. You can also use Pantone matching to create resin of any color you need.
It Supports Limited Materials
As manufacturers use the injection molding process to create cost-effective products in bulk, it’s often believed that it only supports certain parts. But the truth is that injection molding is a highly versatile process, and you can use a variety of materials. This process helps various materials like ABS, polypropylene, and other polymers.
There are thousands of materials available in the market that you can leverage to produce parts with the required configuration. You can pick suitable material based on functional requirements and durability level.
Higher Material Wastage
CNC machining and older injection molding processes used to eat away a significant chunk of the material block. But the latest injection molding processes are efficient and produce the least material wastage compared to other methods. So even if a beginner with minimum training operates the machine, the machine has minimum scrap.
To ensure the machine produces less wastage, engineers need to focus on four key areas — runners, cavity, sprue, and gate locations. By optimizing the settings of these areas, manufacturers can avoid substantial material leakage.
Only Optimizing Molding Parameters Solves Problems
It’s not true, and for improving the overall quality, there are several other things than optimizing the parameters. Factors like warpage, shrinkage, sink marks, and dimensional inaccuracies can help in fixing the product quality issues.
The image is used for illustration purposes. Karv Automation is not the owner or creator of the image. (Image Source: Mastars on Unsplash)
A mold that worked well before doesn’t have to deliver the same performance all time. So, it’s essential to leverage the most compelling part designs. So, you can optimize these parameters before the production begins to ensure top-notch quality.
Final Thoughts
You are now aware of some common myths that you need to keep in mind while opting for it. Injection molding services can help you boost the overall production and take an edge in your business. Whether you need to create prototypes or parts in bulk, this technology suits all your manufacturing requirements.
