Booling plastic injection molding uses advanced production equipment including injection molding machines, dryers, feeders, mixers, and molds. It uses injection molding technology to inject the molten plasticized material into the mold cavity and core through the screw of the injection molding machine. After the pressure-holding cooling process, customized plastic parts are obtained. Booling engineers have rich experience in 2D design, 3D design, CNC programming, and CNC machining and manufacturing, and have helped manufacturers in Germany, Russia, Turkey, Argentina, Canada, and other countries to achieve customized processing and fast delivery of plastic products.
Plastic injection molding has extremely high requirements on the precision and corrosion resistance of the mold, which is usually processed using hardened steel or aluminum alloy to achieve the required number of injections.
- Single Cavity
- Multi-Cavity
- Hot Runner
- Cold Runner
- Two-Plate
- Three-Plate
Plastic Injection Molding Capabilities
Injection molding technology has brought cost-effectiveness to the field of plastic processing and can achieve mass production of products with a high pass rate.
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US
Metric
ABS
59 in. x 51.2 in. x 17.7 in.
1500mm x 1300mm x 450mm
PE
59 in. x 51.2 in. x 17.7 in.
1500mm x 1300mm x 450mm
PP
59 in. x 51.2 in. x 17.7 in.
1500mm x 1300mm x 450mm
PS
59 in. x 51.2 in. x 17.7 in.
1500mm x 1300mm x 450mm
*Plastic injection molding provides extensive material choices, tight tolerances, complex part geometry, high production rates, value-added operations.
Plastic Injection Molding Material
Booling provides plastic injection molding material selection recommendations based on the product’s application scenario, final performance, and structural size.
Plastic Injection Molding Material Selection:
Material
- ABS
- PE
- PP
- PS
- NYLON
- EVA
- Thermoplastic
- PMMA
- Silicone
- Rubber
- LSR
- TPU
- TPV
- TPE
The Advantage of Plastic Injection Molding
Plastic injection molding requires a large initial investment, but the mold can achieve mass production of products and has a long-term return on investment.
- It can achieve mass production of products with multiple materials at a lower cost, and the parts are consistent and high-quality
- Plastic materials can achieve complex shapes and designs through injection molding
- Injection molding can produce parts with stable quality and high dimensional accuracy at a very fast speed
- Using thermoplastics, processing waste can be recycled to reduce material waste
- Booling can directly design the surface texture or logo design directly in the mold cavity, reducing subsequent processing steps
BOOLING Plastic Injection Molding FAQ
Our plastic molding process offers the advantages of high efficiency, high precision, and strong repeatability. This process involves heating a thermoplastic or thermosetting plastic material to a molten state, then injecting it into a mold cavity under high pressure. After cooling and solidifying, the product is formed into a specific shape.
We utilize the latest injection molding machines, environmentally friendly materials, and a professional technical research team to ensure that every mold we manufacture is of the highest quality. If you are still looking for a professional injection mold manufacturer, please contact us.
We are a professional mold supplier with over a decade of experience in precision injection molding. We can customize plastic injection molding solutions for you, providing comprehensive, full-process solutions from product structure optimization and mold design to mass production.
If you require a more precise, customized plastic injection molding solution, you can provide us with photos of your samples to help us understand the product's overall appearance, key structural elements, and special processing surfaces, or send us complete 3D drawings (we support various formats, such as STEP, STL, and SOLIDWORKS).
After receiving an injection molding order, BOOLING mold manufacturers typically perform the following steps to ensure the final product meets customer requirements and is produced on time and within budget:
1. Requirements Analysis: We communicate with the customer to clarify product requirements and specifications. This includes product design drawings, material selection, surface treatment requirements, dimensional accuracy, and more. We also understand the customer's delivery time and budget constraints to prevent misunderstandings and disputes during subsequent collaboration.
2. Quotation and Contract Signing: Our engineers will respond within 24 hours and, based on the project's requirements analysis, calculate costs (including raw materials, processing fees, mold costs, etc.) in a short period of time and provide the customer with a quotation. Once both parties reach an agreement on price and other terms, a formal contract will be signed.
3. Mold Design:
- Mold design is conducted based on the product design drawings, taking into account factors such as plastic flow characteristics, cooling efficiency, and demolding methods.
- Simulation analysis using CAD/CAE software is performed to predict potential issues and optimize the design.
4. Mold Manufacturing:
- Prepare the required materials according to the design and perform precision machining using CNC machines, EDM machines, grinders, and other equipment.
- Heat treat or surface treat key components to improve hardness and wear resistance.
- Assemble all mold components and conduct preliminary commissioning.
5. Mold Trial and Adjustment: Install the newly manufactured mold on the injection molding machine for trial production. Product quality is inspected during the actual injection process. If defects are found, further adjustments to the mold or process parameters are required.
6. Sample Confirmation: Provide initial production samples to the customer for confirmation to ensure that all technical requirements and appearance standards are met. If modifications are required, repeat the mold trial and adjustment steps until satisfactory results are achieved.
7. Mass Production Preparation: Once the samples are approved, preparations for mass production begin. This may include purchasing additional raw materials, arranging production lines, and training operators.
8. Quality Control: Develop a rigorous quality inspection plan, including incoming material inspection, in-process inspection, and finished product inspection, to ensure consistent and reliable quality in each batch.
9. Delivery and After-Sales Service: We will deliver the product according to the agreed-upon schedule and provide necessary technical support and services. If any issues arise during use, we will promptly respond and resolve them.
The above outlines the key steps in BOOLING's entire process, from order acceptance to delivery. Each step requires meticulous planning and rigorous execution to ensure project success and achieve the desired mold result.
1. Raw Material Preparation: Our engineers first select suitable plastic pellets based on the product's properties and user requirements. Masterbatch or other additives are added to adjust color and performance as needed.
2. Plastic Melting: The operator places the plastic pellets into the injection molding machine's hopper and heats them to a molten state using a heating cylinder. The heating temperature depends on the type of plastic used, but is typically between 180°C and 320°C.
3. Injection: The molten plastic is pushed by a screw or plunger into the closed mold cavity at high speed and pressure. This step is crucial to the quality of the final product, and factors such as filling speed and hold time require precise control.
4. Cooling and Solidification: The plastic injected into the mold cavity begins to cool and gradually solidify. To increase production efficiency, a cooling system (such as water cooling) is often used to help maintain the temperature.
5. Mold Opening and Product Removal: Once the plastic has completely cooled and solidified, the mold is opened and the finished product is removed from the mold. An ejector mechanism is sometimes used to assist in this step.
6. Post-Processing: Trimming of excess scraps, surface treatment (such as painting and printing), and assembly are performed as needed.
Application of Plastic Injection Molding
Plastic injection molding technology can produce products with complex structures and details, such as automobiles, consumer goods, medical devices, and electronics.
Guidelines for Plastic Injection Molding
A plastic injection mold is a valuable tool and asset in the injection molding manufacturing process.
The mold is a key tool in plastic injection molding technology. It is usually made of hardened steel and aluminum alloy, with a long service life and corrosion resistance.
Plastic injection molding is the most common method for mass production of plastic products, covering simple daily necessities such as bottle caps and toys and more complex products such as automobiles, aerospace, and medical. It can create more complex shapes and achieve integrated molding. Booling designers will conduct mold flow analysis and provide a feasibility analysis report before production.
Principle of Plastic Injection Molding
Plastic injection molding is a technology that injects molten plastic into the mold cavity for molding, with a high degree of automation and versatility.
Plastics are fed into the barrel in the form of granules or powders. The plastics are processed into a molten state under the action of high temperature and pressure and are pressed into the cavity by a reciprocating screw or syringe. During the filling process, when the cavity is about to be filled, the screw movement quickly changes from flow rate control to pressure control. At this time, it is necessary to properly adjust the back pressure of the screw to compact the melt in the barrel, increase density and avoid surface defects such as bubbles.
After the plastic fills the cavity, it is cooled and solidified. The injection mold is equipped with a circulating water cooling channel to speed up the cooling speed. After the plastic part solidifies, the mold is opened and the part is ejected.
Plastic injection molding is a continuous and repetitive process that can achieve the production of large quantities of plastic parts.
Plastic Injection Molding Process Types
Booling provides single-cavity, multi-cavity, hot runner, insert, over-molding, and other types of injection molds to meet the needs of different products and application scenarios.
- Single Cavity
Single-cavity injection mold is the most basic mold type, producing one plastic part in one cycle, suitable for the production of small batches of products
- Multi-cavity Mold
There are two or more cavities in a mold. The injection molding machine can produce multiple plastic parts in one cycle, realizing precision manufacturing of large-scale products
- Insert Mold
Place prefabricated metal inserts or screws in the mold, and then inject molten material to connect with the insert to improve the overall strength and durability of the product. Insert mold avoids secondary composition and saves time and cost
- Overmolding Mold
Plastic material is injected onto another preformed substrate to reduce assembly costs and improve the overall performance of the product.