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Injection molding GAIM vs. WAIM
GAIM (Gas Assisted Injection Molding) and WAIM (Water Assisted Injection Molding) are advanced injection molding processes that use gas or water to enhance the quality and efficiency of molding parts with varying geometries. GAIM helps create hollow channels, reduces cooling time, and saves materials, while WAIM offers similar benefits with potentially lower costs due to water being used as the medium. Both processes are beneficial for automotive and consumer products, although they come with respective challenges and developmental considerations.
Injection molding GAIM vs. WAIM
- 1. Paul Simons 11-12-2013 GAIM& WAIM gas assisted injection molding water assisted injection molding
- 2. Datum 5 april2022 GAIM gas assisted injection molding
- 3. GAIM ● TSG Group Page3 GAIM (gas assisted injection molding) is a gas-assisted injection molding process where inert gas is injected into the polymer melt through a runner or other designed gas channels.
- 4. GAIM ● TSG Group Page4 The gas cores out a network of hollow channels throughout the mold cavity and drives the polymer melt to complete the filling process.
- 5. When is GAIMapplicable? ● TSG Group Page 5 • Alternative for blowmolding • 2K • Large wall thickness (differences) • Smooth outside of (large) surfaces • Not moldable geometries
- 6. GAIM process ● TSGGroup Page 6 Short injection - Thick sections - Handles, tubular shapes Advantages - Simplify part geometry - Cooling time reduction - Material savings
- 7. GAIM process ● TSGGroup Page 7 Effluence injection Advantages - Surface quality - Material savings - Lower process pressure
- 8. GAIM process ● TSGGroup Page 8 Full injection - Shell shaped parts - Parts with thin sections Advantages - Surface quality - Dimensional stability - Lower clamping force
- 9. Important variables GAIM ●TSG Group Page 9 • Place of material injection • Place of gas injection • Quantity of injected plastic before gas is introduced • Dimension gas channels • Position gas channels
- 10. Lower filling andpacking pressure and clamping tonnage Reduction of closing force > larger products possible Decrease machine power consumption Shorten cooling time Material saving by hollow tubes and rod-shaped products Less wear and maintenance of mold Production Advantages GAIM ● TSG Group Page 10 + + + + + +
- 11. Prevent sink marksand warpage of flat products. Save significant weight and material. Reduce residual stress. Increase dimensional stability. Simplify product design. Integration of inner tubular geometry. Improve surface quality and rigidity. Products with large differences in geometry thickness, e.g. by combining different components. Product Advantages GAIM ● TSG Group Page 11 + + + + + + + +
- 12. Disadvantages GAIM ● TSGGroup Page 12 License costs (Cinpres) Fingering Control of gas path Race tracking of polymer through gas channels Blow-through of gas More expensive than standard IM - - - - - -
- 13. Design features GAIM ●TSG Group Page 13 • Robust appearances • Tubular shapes • Large smooth surfaces • Thick/thin sections in one design
- 14. Design features GAIM ●TSG Group Page 14 • Robust appearances • Tubular shapes • Large smooth surfaces • Thick/thin sections in one design
- 15. Design features GAIM ●TSG Group Page 15 • Robust appearances • Tubular shapes • Large smooth surfaces • Thick/thin sections in one design
- 16. Design features GAIM ●TSG Group Page 16 • Robust appearances • Tubular shapes • Large smooth surfaces • Thick/thin sections in one design
- 17. Cornering effect GAIM ●TSG Group Page 17 The 'cornering effect' is an uneven wall thickness distribution in curves. Use large radii in corners to avoid thin wall thicknesses in the inner corners
- 18. Cornering effect GAIM ●TSG Group Page 18
- 19. Product examples GAIM ●TSG Group Page 19 Automotive: panels, door handles Garden furniture SAT dishes TV and printer housings
- 20. Materials GAIM ● TSGGroup Page 20 PP, PBT, ABS, PC-ABS, PVC, PA, PET, PS/HIPS, PPE
- 21. Simulation tool GAIM ●TSG Group Page 21 Moldex3D Gas-Assisted Injection Molding (GAIM) visualizes the 3D flow behavior in combination with the gas that is injected into the mold cavity through the sprue and / or gas intended feeding points.
- 22. Simulation tool GAIM ●TSG Group Page 22 Typical gas injection issues such as fingering effects' (gas foothills), blow-through (through the wall release of gas) or corner effects, can be predicted to give the actual injection molding process, users understand and improve the producibility.
- 23. Datum 5 april2022 WAIM water assisted injection molding
- 24. WAIM ● TSG Group Page24 WAIM (water-assisted injection molding) is an injection molding technology that has been developed from the technique of GAIM. The idea is the same except that the medium is water instead of inert gas.
- 25. WAIM ● TSG Group Page25 Water serves as a cheap medium together with a high heat capacity and thermal conductivity, resulting in a short cycle time.
- 26. WAIM process ● TSGGroup Page 26 Water injection Specifications • Water injection> 1 l / s • Removing water through gravity • Blow with compressed air from another position • Injection of pressurized air through nozzle where water goes through • Vacuum
- 27. Reduces cooling cycletime Thinner walls, less material Material surface and performance Proven process technology, materials Water is a low-cost media No remaining ingredients of water in moldings Water is incompressible Direct internal cooling of moldings Product Advantages WAIM ● TSG Group Page 27 + + + + + + + +
- 28. Disadvantages WAIM ● TSGGroup Page 28 The influence of the material properties to the residual wall thickness is not precisely known You experience wall defects such as fingering and double wall that the mechanical properties of the product reduced - -
- 29. Maturity of WAIM ●TSG Group Page 29 WAIM has been under development for some 10 to 15 years and is already successfully commercialized in Europe. In North America, BASF Corporation has built upon its European experience and established WAIM technology and application development capabilities. At its Budd Lake, New Jersey, location, the company can perform pilot-scale WAIM, gas-assist injection molding, or the combination of the two processes (GAS-WAIM). BASF has already optimized several resin grades specifically for use in WAIM or GAS-WAIM, and in several product applications.
- 30. Products examples WAIM ●TSG Group Page 30 Automotive: door handles, canals for coolant and oil Handles: ovens, refrigerators, tools Armrests for office chairs Structural elements
- 31. Simulation tool WAIM ●TSG Group Page 31 Moldex3D Water-Assisted Injection Molding WAIM is a 3D simulation tool that allows users to visualize water penetration into the mold cavity and in order to dive the mold design and to optimize the process. Parameters further in the process
- 32. Datum 5 april2022 WAIM vs GAIM
- 33. Benefits WAIM &GAIM ● TSG Group Page 33 Smooth (and/or defined) surface Faster cycle time Hollow products possible Weight reduction Lower material consumption Lower tool costs More part consolidation and less finishing than with un-assisted injection molding or metals Mechanical strength and dimensional stability to thick injection molded products by material savings without compromising on quality. + + + + + + + +
- 34. WAIM vs GAIM ●TSG Group Page 34 Approx. 50% shorter cycle time WAIM vs GAIM On average 25% thinner walls WAIM vs GAIM Heat capacity of water is 4x that of gas Improved thermal conductivity of water compared to gas Uniform wall thickness at bends
- 35. Disclaimer ● TSG Group Page35 Photos and other graphic content of this presentation are used for educational purposes only and is proprietary of the original owners. TSG Group cannot be held liable in any way.
- 36. ● bedankt p.simons@tsggroup.nl Thank youfor your attention!