This document discusses advances in injection moulding technologies, including multi-component injection moulding, in-mould labelling, gas assisted injection moulding, thin wall injection moulding, and micro injection moulding. It provides information on each technology, including their classification, processes involved, advantages, applications, and introductions. The document aims to present new developments in injection moulding that provide benefits such as reduced costs, increased functionality and quality, and new design possibilities.

1. ADVANCES
IN
INJECTION
MOULDING
PRESENTED BY :
LOKESH KUMAR GAHOI
3 rd BTECH PLASTIC
TECHNOLOGY
SR. NO. :- 459/10

2. CONTENTS
 INTRODUCTION
 ADVANCED INJECTION MOULDING TECHNOLOGIES
1. MULTI – COMPONENT INJECTION MOULDING
2. IN – MOULD LABELLING
3. GAS ASSISTED INJECTION MOULDING
4. THIN WALL INJECTION MOULDING
5. MICRO INJECTION MOULDING
 CONCLUSION

3. INTRODUCTION
• Injection molding technology continually develops, with major
milestones including the introduction of the first thermoplastic
materials, the reciprocating screw design, the first hot runner
systems, engineering materials, the introduction of
microprocessors for machine control and recently the
application of expert systems for optimized machine setup.
• Injection molding of thermoplastics has emerged as the
premier vehicle for delivering high quality, value added
commercial products. Perhaps due to this success, there has
been sustained pressure for increased standards of molded part
quality while requiring reduced product development time and
unit cost.

5. INTRODUCTION
 A large number of polymeric materials with different
degrees of hardness and colours can be combined and
processed
 This technology offers the possibility of combining
various product features with low assembly cost.
 Greatest possible variety of combination options: up to six
independent injection units on a single machine

6. CLASSIFICATION
According to the no of sprue , multi - component injection moulding
can be classified as :

7. THE SANDWICH PROCESS
1 . Injection of outer
component = skin
2. Injection of core
material into
component 1.
3. Finished product with
hard core and
comparitively softer
CAVITY SEPERATION PROCESS skin
1. Injection of outer
component 1
2. Pulling back of slide
3. Injection of
component 2

8. THE TURNTABLE PROCESS
1 . Injection of inner
component
2. Rotation of moving
mould half on
turntable
3. Simultaneous injectio
of component 2 and
component 1.
THE TRANSFER PROCESS 1. Injection of component
1
2. Transfer of the
substrate
to a new cavity .
3. Injection of component
2.
Simultaneous injection
of the next substrate.

9. ADVANTAGES
ENHANCED APPEARANCE
• By incorporating multiple colored materials, creating soft touch
areas and enhancing fine detail and aesthetics improving product
appeal.
COST REDUCTIONS
• Combine two parts into one for savings in materials, production,
handling and inventory, and eliminating post molding assemblies
such as snap fits, welding, adhesives, mechanical fasteners and
seals.
INCREASED FUNCTIONALITY
• Allows for new design possibilities with multiple components in
a single part, increased complexity and parts with movable
segments or components using “in mold assembly”.
IMPROVED QUALITY
• Two shot molding technology lowers tolerances, improves

10. APPLICATIONS
 Car sunroof with integrated assembly elements
 Colour sorted tooth brushes
 Housing of various items like powertools etc.
 Wind deflector with integrated gasket
 Automotive rear lamp cluster
 Handles of refrigerator doors

11. The technology was first developed by OWENS-ILLINOIS in cooperation
with PROCTER & GAMBLE .
This was first applied to HEAD & SHOULDERS shampoo bottles.

12. INTRODUCTION
In the in-mold labeling process, a label or applique is
placed in the open mold and held in the desired position
by vacuum ports, electrostatic attraction or other
appropriate means. The mold closes and molten plastic
resin is extruded or injected into the mold where it
conforms to the shape of the object.

13. PROCESS

14. ADVANTAGES
Lower costs than other pre-decorating methods.
No extra labeling step or equipment.
Increased packaging line speeds.
Reduces in-house container inventory.
Reduced container weight.
Improved appearance.
Better stain resistance.
Improved sidewall strength.
Up to 5 color process in one shot
Higher durability / scratch resistant
Impervious to UV, power washing, gas, acid and other outdoor
conditions
Enables shoot & ship
Less scrap / waste

15. APPLICATIONS
Outdoor Durable and Packaging
Barcode, including sequential barcodes (for tracking)
Shampoo bottles
Single and Multi-Cavity Applications
Vacuum or Static Label Placement (direct or remote)
Specialized Cup Automation Cells (singe and multi-
cavity, two plate or stack mold)
Label Nest (with/without motion)
Custom Human Machine Interface (HMI)

16. IN MOULD BARCODE LABELS
• For the In-Mould Labeling process, special labels are placed inside the cavity of the
injection-molding machine. The labels fuse completely with the plastic and are fully
integrated onto the surface of the item. A special surface treatment makes these labels
particularly resistant to wear and tear, UV light, cleaning products, weak acids and
chemicals.
The label is bonded to the container during the injection moulding process, leaving a
smooth, rimless surface, which means that no dirt or moisture can get in underneath
the label.
• In terms of durability and hygiene, this process is unsurpassed. It also meets the
highest aesthetic demands
• Permanent identification of reusable containers

18. INTRODUCTION
This method is used to create one or more hollow
channels within an injection-molded plastic part.
Gas (N2) is injected into the still liquid core of the
molding at the end of the filling stage.
Gas follows the path of the least resistance.
Thick molten sections get replaced with gas-filled
channels.
Finally, the gas is vented to atmosphere or recycled .

19. G.A.I.M. PROCESS

20. PROS AND CONS
PROS CONS
 Cycle time reduction and
 Not fully being able to
lower production costs
control where the gas goes
 Material saving for thick
 High cost of tooling and
walls upto 80 %
mould flow analysis
 High rigidity due to hollow
 Penetration of gas from gas
rib formation by design
channel into thinner section of
 Lower clamping forces
the part
 High flexural stiffness and
 Slow cooling time of mould.
mould
torsional rigidity
 Reduction of sink marks.

21. APPLICATIONS
 Door Hardware Module.
 Auto Side Mirror Housing.
 Auto Door Handle.
 Auto Bumper.
 Auto License Plate Holder.
 CD-ROM Tray.
 Power Amplifier Housing.
 Truck Air Filter Housing.
 Water Cooler Housing Panels.
 Hospital Bed Rails.
 Appliance Handle.
 Wheelchair Wheel.
 Washing Machine Agitator

23. INTRODUCTION
TWIM or Thin wall Injection Moulding has been paid more and more attention,
especially in computer, communication and consumer electronic (3C) industries,
due to economic and environmental concerns.
The reason is that thin-wall molded parts could be made lighter, more compact,
less expensive, and quicker because of fast cooling
Thin wall plastic food containers are becoming more and more popular. The
thermoforming disposable containers are considered to cost more of electricity
power consumptions and complex process. As you know, thermoforming process
is two stages, it needs the shape forming from the plastic sheet, the plastic sheet
extrusion molding are complex too. From the
sheet being heated until the vacuum forming and deflashing…

24. STANDARD VS. THIN-WALL PROCESSING
Key Factors Conventional Thin-Wall
Typical Wall 0.080-0.120 0.050-0.080 <0.050
thickness, in.
Machinery Standard High-end Custom
Inject. Pressure, 9000-14,000 16,000-20,000 20,000-35,000
psi
Tooling Standard Better venting, Extreme venting, very
heavier heavy construction,
construction, mold interlocks,
more ejector precise surface
pins, better preparation, extensive
polish ejection features,
mold costs 30-40%
higher than standard.
Control System Standard Closed-loop on Same as at left, with
injection speed, resolution of 0.40 in.
hold pressure, on speed, 14.5 psi on
decompression pressure, 0.004 in. on
speed, screw rpm, position, 0.01 sec on

25. THIN WALL INJECTION FLOW
 Thin wall parts require higher injection
pressure because the distance that the material
can flow is dependent on the thickness
of the part. As the following Illustration shows,
the material Forms a frozen skin on the outside
walls of the cavity first And then starts to solidify
towards the centre. The centre of the flow is the
last To solidify. If your wall section is very thin
then this solidification occurs very quickly.
 Melt streams should reach all the boundaries
of mould before melt freezes.
 Freezing time is proportional to cube of wall
thickness. Therefore, for thinner wall, melt
should flow fast enough to ensure that melt fills
fully before it freezes. Hence, max injection rate
of machine is important specification of machine
to
determine spread of melt through longest flow

27. ADVANTAGES
 Cheap, safe and clean plastic parts.
 Allows faster cycle times compared with thicker walled plastic
parts.
 Lighter parts reduce fuel emissions in automotive applications.
 Thin wall molding reduces resource consumption and cuts
weight, reducing fuel usage and carbon emissions in shipping –
further supporting sustainability efforts.
 Made from recyclable plastics such as polypropylene (PP) in
food packaging.
 Some thin wall parts can be made from sustainable plastics.

28. LIMITATIONS
• Environmental litter.
• High capital investment cost for injection molders. Thin wall
molding requires specialized molding machines, injection
molds and robots that can withstand the high stresses, fast
cycle times and relentless 24/7 production schedules.
• To make thin wall parts we requires highly skilled molding
technicians and these are difficult to find and keep .

29. APPLICATIONS
The following industries make
use of thin wall molding:
food packaging ( eg. food containers
and lids)
automotive (eg. both structural and
non-structural car parts)
mobile telecommunications (eg.
mobile phone housings)
medical (eg. syringes)
computing equipment (eg. computer
housings)

31. INTRODUCTION
Micro Injection Molding is a special plastic moulding technique.
The plastic parts made by means of micromolding have a weight less than
0.1 gr, or have structuraldimensions with less than 1 mm.
This processing technology needs the use of quite special methods for the
manufacturing of mold, and of course the injection of plastic material.
One of the hurdles limiting the current technical capability in micro
injection molding is that the molten polymer in a tiny cavity instantaneously
freezes upon contacting the relatively cold cavity wall.
The main objective is to develop a novel technology for successful micro
injection molding with respect to lower cycle time, better replication and
better mechanical and optical quality as compared to the existing technology.
This objective will be accomplished by rapidly heating the mold surface so
that the melt can fill the cavity isothermally and yet be processed within the
normal injection molding cycle time

32. POLYMERS FOR MICROMOULDING
• LCP (Liquid Crystal polymers)
• Acetal (polyoxymethylene POM)
• Polyester
• Polycarbonate
• PEEK (Poly ether ether ketone)
• Glass and Mineral filled compounds adds to the
rigidity and stability
• Materials like Nylons are not suitable for micromolding
since
they change size making it difficult to hold close
tolerances

33. 2 STAGE MICRO INJECTION
UNIT

34. ADVANTAGES
 Tooling is less expensive.
Typically a micro injection molding machine running 2 to 4 cavities can
compete with a standard molding machine having 16 cavities. Fewer cavities
mean lower tooling cost and higher quality.
 Parts are more accurate with less dimensional variability.
 Cycles are very fast.
Faster cycle times mean lower cost. Cycles typically run less than 6
seconds and often as low as 3 and 4!
 Radical part geometries possible.
 Very thin walls with filled engineering materials are possible.
 Defined colours

35. CHALLENGES

36. APPLICATIONS
AUTOMOTIVE
TELECOMUNICATIONS
ELECTRONICS
MEDICAL
SENSORS
OPTICS
WATCH INDUSTRY

37. CONCLUSION
 Due to the various advantages in multicomponent
injection moulding , this method is used in wind deflector
with integrated gaskets, automotive rear lamp cluster etc.
 In mould decoration is a derivative of inmould labelling
technique and is the future to decorative fashion and
design.
 Hollow articles of light weight with better finish can be
produce by Gas assisted injection molding.
 Thin-wall molded parts could be made lighter, more
compact, less expensive, and quicker because of fast
cooling
 Micro and nano injection moulding is the future of
moulding technology

38. REFERENCES
• www.arburg.com
• www.raumedic.com
• www.wikipedia.org
• www.dakumar.com
• www.4spe.org
• www.mastip.com
• www.milacron.com

39. Thank you
for the
Thank you
attention
for the attention
THANK YOU FOR THE ATTENTION