Post views: 563
Plastic injection molding is a widely used manufacturing process for the manufacture of plastic components and various everyday plastic objects. It is a very reliable, simple and efficient process that is used in several industries, including the medical, aircraft, automotive and toy industries. It is a fast and time-efficient production process that enables the production of large quantities of the same plastic output in a short period of time.
However, budget is one of the most important considerations a manufacturer needs to consider if they want to get a product to market quickly. Making a brand new plastic item involves a variety of considerations that can have a significant impact on cost, including component design, manufacturing time, pressure and temperature used, and the type of resin used.
Control of the Plastic injection molding Cost requires analyzing various factors, whether you are in the initial design phase, prototyping or manufacturing. Still, some tricks can be used to save money, especially on injection mold production costs.
The following sections show you how you can reduce the cost of plastic injection molding without compromising your design goals.
Your plastic designs should use as little material as possible, which is often referred to in the manufacturing industry as minimalist design. Using fewer materials results in lower costs, but that doesn’t mean your plastic product loses functionality.
Proper minimalist design is functionally efficient and helps minimize cycle time for cooling and molding. Consider structural support in relation to the connectors and choose hollow rather than large designs. Plastic injection molding companies can usually provide support.
The commitment to have a little more in your plastic design means a higher molding effort and cost. Methods such as bead blasting, mirror polishing, EDM, and others may be required to maintain the aesthetics and additional features intended for your plastic design. Unless strictly necessary, these methods will no doubt affect the goal of inexpensive injection molding.
Before starting manufacturing, it can be beneficial to carefully examine the structure of your part to determine which sections are most important to its function and quality. By doing this in-depth study, you may discover places where a gusset or rib instead of a completely solid section provides the strength you need.
These types of design changes, when combined, can increase the structural integrity of your product while also making it easier to manufacture. In addition, thanks to the reduced weight of the parts, your end product is cheaper to transport, store and deliver.
You don’t have to buy new molds for every batch of products you create. With careful preparation, you can Reuse shapes several times by simply modifying and adding construction tool inserts that change the shape design and accept various functions.
The MUD tooling method, which creates a smaller cast from the existing foundation of the original shape, is the most widely used shape modification method available. The smaller shape can be used for a variety of different functions and plastic finishes. These modifications are known to help minimize the cost of custom injection molding plastics and are great for plastics manufacturing companies that do multiple designs in their molds.
Tool design and configuration can have a significant impact on the efficiency and costs of both the tool shop and your component manufacturing process when developing box-shaped or cylindrical items. For hollow molds of this type, the “core cavity” design is an excellent choice.
The term Core cavity refers to the fact that the tool is machined around the cavity shape rather than constructing a mold half with deep, thin walls to create the cavity. The design is much simpler and less prone to error, and the flow of materials becomes much smoother throughout the manufacturing process. Better still, this makes it easy to create clean surfaces, adequate ventilation, improved ejection, and eliminates the need for very steep draft angles.
This is about lowering your cost per part, which can help you recoup the cost of your mold over a larger volume of parts produced and lower your overall investment by improving manufacturing process efficiency.
If you can make a mold with five instead of two shots, you increase your production speed significantly, cause less wear and tear on your mold, and you can get to market faster.
In certain circumstances, you can even reduce your tooling costs by using a less expensive material because with more shots the mold will go through fewer cycles to make the same number of parts.
Minimizing the use of cosmetics and features doesn’t mean you want to compromise on your plastic designs. Aesthetics are important, but excessive and unnecessary ornamentation adds cost and requires more effort to manufacture
To reduce injection molding costs, keep your plastic designs simple by sticking to the essentials, such as: B. polishing. Unnecessary hooks and edges as well as unnecessary curves should be avoided.
A Family or multi-cavity mold has incorporated more than one cavity so that many components can be manufactured from the same material in the same cycle. Usually each cavity generates a unique component number.
Making a family mold is a great approach to reducing injection molding costs. It can accommodate multiple parts in the mold, as long as the materials are chemically comparable and have similar processing properties.
A family tool can be more expensive than a traditional tool, but when the blanks and separate tools for each design are contained within the tool, the injection molding costs can be saved significantly.
When building a junction box for certain medical components or two interlocking halves of a portable radio, you shouldn’t make two mating pieces when one is enough. Redesign the snap fasteners so that the halves can be joined together from both sides, resulting in what is known as a “universal” component.
In such cases, only one mold is needed, which reduces the up-front costs of production. Also, you can now shape twice as much of one part instead of half as many of two.
Plastic injection molding is an established technology, and because of its fundamental approach, methods may no longer exist to improve it. However, if you delve deeper into the world of plastics manufacturing, you will find that there are many more processes that can help reduce injection molding costs or take advantage of inexpensive plastic molds in a high quality production process.
By following the eight recommendations above to minimize injection molding costs, you can optimize your bottom line and earn more while spending less.