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Thin wall injection molding
Thin wall injection molding is a process involving parts with wall thicknesses often less than 0.6 mm that allows for lightweight and complex shapes with improved flow characteristics. It is used mainly for packaging and disposable containers, enabling shorter cycle times, higher productivity, and cost savings due to reduced material usage. Key considerations include machine selection, optimized settings, and overcoming limitations such as high material stress and the need for precise control during the molding process.
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Thin wall injection molding
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- 2. why design wiThPlasTic ? • Excellent Barrier resistance • Non Toxic Properties • Odorless • Easily formed into complex shapes • Wide choice of appearance, colors and transparencies
- 3. maTerial ProPerTy forThin wall molding • Improved flow ability : permits luxury with odd geometry in shapes • •Low density & packing weight permits affordable cost to performance • •Excellent toughness to withstand against content • •Optimal combination of flow, impact resistance & stiffness • •Stack ability for ease of bulk transport. • •Excellent stiffness for the freedom of attractive shape & size • •Superior clarity & crystalline for the product visibility.
- 4. Thin-Wall injecTion Molding • Whatis “ Thin Wall Injection Molding’’ ? –• Wall thickness often <0.6 mm –• Parts with flow ratio >150 –• High Injection pressure –• High Injection speed –• Applications for containers in packaging and storage as well as disposable use.
- 5. FasT cycling Molding– Key RequiReMenTs • A mold which is capable to run fast cycles for a long period • A capable injection molding machine • Consistency in Raw Material • Production environment with essential well define Auxiliaries • Cooling water for molding machine • Fast and precise machine movements for prolonged period.. • Chilled water for mold • Energy saving operation
- 6. Reasons FoR “ThinWall injecTion Molding” • Less material per part means less material cost per part • Thinner wall thickness means shorter cooling time and therefore shorter cycle time resulting towards, • Higher Productivity –High Profitability
- 7. Machine Selection criteria • Highercavity pressures result in higher necessary Clamp forces. • High Injection Pressure with > 2200 bar. • High acceleration with accumulator- power > 350 mm/s. • Faster Response of controller within 2 mili seconds to be synchronized by Smart hydraulic for the shortest cycle time.
- 8. Machine Setting for“Thin Wall Injection Molding” • Nearly no holding or packing necessary • Often Injection against mechanical stop in the injection unit with no cushion • Start injection before clamp force is fully built for better venting • Short cooling time • Optimized machine movements for short cycle time • Parallel machine movements
- 9. Selection of injection Unit •Important factors: –•Screw torque –•Melt temperature –•Injection rate and pressure –•Cycle time - cooling time –•Plasticizing rate –•Repeatability –•Screw Geometry
- 10. Mould Selection criteriafor “thin Wall injection Molding” • Short runner channels to reduce flow length and pressure losses • • Hot runner is preferred compared to cold runner systems • • Gate bigger in size because of higher volume flow through cross section • • Special arrangement for gating like cascade or sequential injection; per part multi-gating
- 11. liMitationS of “thin-Wall injectionMolding” • To high material stress • • Flow properties of material • • Residence time for material because of smaller shot weights • • Economical situation, related to investment costs compared advantages
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