You have certainly wondered how electronic objects around you. We have already discussed the 3D plans and software for our calculator, but we would also like to share your entire high gloss mold manufacturing process with you.
The production of a device includes many steps, from the manufacture of the molds to the packaging. So let's start at the beginning: the plastic injection.
High gloss mold Plastic injection molding
The vast majority of plastic products we use daily are injected, from disposable knives to garden chairs. This allows us to produce parts with the most varied shapes at a very high rate, with a reasonable unit cost. And our calculator is no exception!
Plastic injection molding is a simple concept: a hollow block - the mold - comes with hot plastic in a viscous state. And when the plastic has cooled and solidified, the resulting part is removed. It sounds very simple when put like that, doesn't it? In practice, it is a little more complicated to explain and so this is the first in a series of articles.
The simple plastic injection mold
Take for example the back cover of our calculator, which is the simplest part of this product.
Let's first assume that the high gloss mold is whole. We could fit the still-liquid plastic through an opening. But how would we remove the solidified part from inside the mold?
There would be an option to break the mold, but that meant making a new mold for each piece produced. Now, the cost of making a mold is much higher, because it is necessary to cut. We are talking about machines - extremely resistant steel. And in any case, it is impossible to excavate a steel block through a small opening.
Therefore, the simple solution is to have a mold in two halves. A little like making waffles!
In a simple mold, one part is fixed and the other is movable. As soon as the mold is filled with plastic and it solidifies, the mobile part of the mold moves away, dragging the produced plastic part with it.
In order to separate these two parts, long metal rods are placed in the mold, distributed over the entire interior surface of the mold: the so-called extractors. The extractors are responsible for pushing the produced part, forcing it out of the mold. When placed at key points, they facilitate the extraction of the piece from the mold.
How to optimize high gloss mold production time?
In order to optimize the high gloss mold production time, the plastic part is ejected from the mold before cooling completely. This means that its surface is still warm and slightly soft when the extractors do their job. It will leave a round mark on the surface of the piece.
The marks of these extractors can be seen on many everyday objects, from knives to plastic chairs. In products that are assembled from several parts, such as our calculator, the extraction marks are hidden inside the parts and, therefore, are invisible in the final product.
Once removed from the mold, an operator makes the first touches and checks if the part is defective. If you pass this first test, you are ready to continue production!
BLOW, INJECTION AND THERMOFORMING SOLUTIONS
The molding of plastic parts blow may be regarded as one of the most difficult processes to be made. It is necessary to combine the extrusion must be done in the funnel until the mold with the part forming process when it is still inside the mold.
This procedure is widely used in the construction of hollow pieces such as drums and bottles.
All this work is not something easy to do, as it requires specific fluidity. And this is only found with a certain limit in the thermoplastics used. And where it is easier to find these requirements are: HDPE, PVC and PP.
How does the blow molding process work?
To start the process of molding plastic parts by blowing, the crushed or granulated plastic is placed directly in the hopper of the machine. The first process, classified as normal, is extrusion. In it, all content will be transported to a thread using a cylinder.
In this first high gloss mold stage, it starts to be melted due to the heat and the friction to which it is submitted together with the action of the electrical resistances that are fixed on the outside of the cylinder.
When the granulated plastic passes through the die of the extruder unit, all the material is transformed into a hose that is known as parison.
Therefore, the mold closes on this hose and it is cut before an air nozzle is even placed in the parison so that it can be blown and take the shape of the mold you want. The plastic part is then cooled and the mold is opened and the produced part is removed.
Advantage in the use of high gloss mold of plastic parts
One of the advantages of resorting to blow molding of plastic parts is the fact that this feature is considered to have cheaper tools. It is for some product geometries when compared to the injection process.
This is because the blow mold of plastic parts does not require in most cases it does not require as many mechanisms and it can be built with aluminum or copper and steel alloys.
It is important to note that within the process of molding plastic parts by blowing. There are many variants as to the common blowing procedure which is called: injection high gloss mold.
The machine that performs the injection-blow has an injection mold and a blow mold. It is mostly used to produce flasks or pet bottles, because it makes parts that do not get burrs.
High gloss mold Plastic Parts
Looking for a company that operates with blow molding of plastic parts? We have been working in this field for many years, manufacturing parts for the automotive, home appliance, civil construction, agricultural and many others sectors.
To find out more about our products and / or services just contact us. Our team is ready to answer all your questions!
Do you have any questions about making injection molds? In this text, our goal is to answer some of these main questions. But if you still can't find the answer, get in touch, as we will answer with the greatest pleasure.
Why high gloss mold is popular?
For many years, the manufacture of high gloss mold injection molds has been growing. It is necessary to meet the demand from the packaging, automotive, food and other industries.
The designer is responsible for developing the injection mold. But for that, he will need to consider where the mold will be used. And through software he will develop the project taking into account the needs of his client.
Before even sending to production, the lines and cavities are defined, and all the design characteristics, after the materials are defined and sent to production.
Questions about the manufacture of injection molds: how is the whole process done?
We can define the whole process as something extremely delicate! This is because the injection molds that are used in vehicles, electronics, phones and cell phones must be extremely accurate parts. However, they are also very complex and need to have their own manufacturing equipment.
The materials used in the manufacture of high gloss mold injection molds are special steels, carbon steel, as well as metallic alloys that are classified as special. However, it is also possible to use aluminum alloys for making molds that will only serve as prototypes or for low production.
Questions about high gloss mold injection mold manufacturing
The refrigeration process is very important in the manufacture of injection molds, because refrigeration is largely responsible for making the plastic mass solid and thus, the manufactured product will have all the necessary dimensional stability to function.
In addition, refrigeration reduces the production cycle time and, as a consequence, the process becomes more productive. After being cold, the product is then removed.
Working on a vacuum forming equipment consists in heating all layers of a plastic sheet using infrared heating lamps that emit heat absorbed by objects.
Benefits of thermoplastic vacuum forming
We have selected the main criteria for the positive operation of vacuum forming equipment.
- The thickness of the processed sheet varies from 0.1 to 10 mm. When using pneumatic vacuum forming equipment, it is possible to process sheets up to 60 mm thick, and the size of the blank sheet is several meters in diameter.
- Reduced production costs. Low load, reduced complexity of plastic processing makes this method cheaper than injection molding.
- Reduced processing time and raw material costs, taking into account the entire production process. Due to the low cost per die, the manufacturing costs of the product are reduced.
After the blank sheet has warmed up, it is placed behind the mold, and the rest of the air is pumped out using a vacuum. The pressure created by the machine forces the plastic mold to take the shape of the workpiece, transferring small parts to the surface.
After solidification of the plastic, the resulting form is taken out of the mold and transferred to further processing. Then the part goes to assembly, machining, painting or cleaning.
Do you have any doubts about gloss mold?
Was there still any doubt about the high gloss mold injection molds? Get in touch with our team, as we will be happy to help you and, furthermore, we are able to propose solutions that will make your business more and more profitable, as it now has our items.