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Injection molding is a popular manufacturing method for many reasons. It has proven especially valuable to those in the consumer product development sector, since plastics are a primary component of many consumer products, and injection molding is one of the best ways to manufacture plastics. Let’s take a quick look at the three major phases of the injection molding process, and then discuss the advantages and disadvantages of the process.
Injection Molding Process, Basic Step 1: Product Design
Design is one of the most important facets of the production process because it’s the earliest opportunity to prevent expensive mistakes later on. (Of course, determining whether you have a good idea in the first place is also important, but more on that here.) There are many objectives to design for: function, aesthetics, manufacturability, assembly, etc. The right design is one that accomplishes the required objectives to a satisfactory level, but it may take a lot of creativity to get there. Product design is most often accomplished with computer aided design (CAD) software, like SolidWorks. (Click here for nine pro tips on how to best use SolidWorks in design and engineering.) Proficiency with CAD software is vital because it allows for quicker iterations and more accurate prototyping if necessary.
Design and engineering for injection molding
Some specific ways to avoid costly mistakes during the product design process are to plan for uniform wall thickness whenever possible, and to gradually transition from one thickness to another when changes in thickness are not avoidable. It is also important to avoid building stress into the design, such as corners that are 90 degrees or less. (Read more about Injection Molding Defects here.)
A skilled team of design engineers will be able to brainstorm, design, and improve upon a variety of solutions to meet the particular complexities of a specific project. The design team at Creative Mechanisms has combined decades of experience creating elegant solutions to complex problems. Meet some of our team here, here, or here, or visit our Customer Testimonials page to see what previous and current clients have to say about our product design capabilities. We think you’ll be impressed.
Injection Molding Process, Basic Step 2: Mold Design
After a looks-like, feels-like design has been tested and slated for further production, the mold (or die) needs to be designed for injection mold manufacturing. Molds are commonly made from these types of metals:
Hardened steel: Typically the most expensive material to use for a mold, and generally the longest-lasting (which can drive down price per unit). This makes hardened steel a good material choice for products where multiple hundreds of thousands are to be produced. Prehardened steel: Does not last as many cycles as hardened steel, and is less expensive to create. Aluminum: Most commonly used for single cavity "Prototype Tooling" when a relatively low number of parts are needed for testing. Once the injection molded parts from this tool are tested and approved, then a multi cavity steel production tool is produced. It is possible to get many thousands of parts from an aluminum tool but typically it is used for lower quantities.
