Injection Moulding

Injection Moulding, along with extrusion ranks as one of the prime processes for producing plastics articles. It is a fast process and is used to produce large numbers of identical items from high precision engineering components to disposable consumer goodsMost thermoplastics can be processed by Injection Moulding, following are the most commonly used by Mapco:Polystyrene Polypropylene Polycarbonate Nylon Acrylonitrile-Butadiene-Styrene The essential elements of the process are as follows:Material is introduced into the injection moulding machine via a Hopper. The injection moulding machine consists of a heated barrel equipped with a reciprocating screw (driven by a hydraulic or electric motor), which feeds the molten polymer into a temperature controlled split mould via a channel system of gates and runners. The screw melts (plasticises) the polymer, and also acts as a ram during the injection phase. The screw action also provides additional heating by virtue of the shearing action on the polymer. The polymer is injected into a mould tool that defines the shape of the moulded part. The pressure of injection is high, dependant on the material being processed; it can be up to one thousand atmospheres. Tools tend to be manufactured from steels, (which can be hardened and plated), and Aluminium alloys for increased cutting and hand polishing speeds. The costs associated with tool manufacture means that injection moulding tends to lend itself to high volume manufacture.The tool can be used to manufacture one consistent part in a repeating process or incorporate multi cavities (a multi impression tool), that is many components can be manufactured on the same tool repeatedly with a single injection. It should be noted that, whilst in the animation the flute pitch of the screw is shown as constant along its length, in practice it varies considerably dependent upon the polymer being processed. In particular the root diameter increases from hopper to nozzle to provide compression to the melt.Variants of the injection moulding process include multi-shot (or 2K moulding) (where different materials are injected into the same mould), insert moulding (where metal components are incorporated), structural foam moulding (where the material is foamed to reduce density) and assisted moulding (where gas or water are incorporated to reduce wall thickness).