High speed injection moulding machine

Types of High-Speed Injection Moulding Machines

The high speed injection moulding machine employs different technologies to increase the pace of plastic part production. Here are the common types based on their diverse functional technologies.

• Flow Accelerated Injection Machines

  This machine uses a controlled melt flow to shorten cycle times. Usually, it lowers pressure at the start of injection to increase piston speed. The machine achieves faster filling times without increasing scrap rates or energy use.

• Cyclone Injection Molding Machine

  The cyclone machine has a vortex chamber that cools extruded molten plastic. The chamber eliminates the need to wait for excessive cooling. It also reduces cycle time dramatically. In addition, the molding machine provides uniform melt distribution and pressure.

• Accurate Control Molding Machines

  This type of machine uses the fast-response technology of hydraulic and electric drives. It achieves shorter cycle times by reducing the delay in the execution and transmission of control signals. Furthermore, it ensures precise control of the timing and speed of each injection phase. Ultimately, the machine provides optimal injection rates with minimal waste.

• Multistage Injection Molding Machines

  The machine achieves rapid production by using two or more injection cycles within a single molding cycle. Additionally, it allows for the sequential or simultaneous injection of different materials. It also provides better flexibility in producing complex shapes with shorter cycle times.

• Double Shot Injection Molding Machines

  This machine combines two shots of molten material into one cycle. It reduces material waste and molding time. Additionally, it produces complex parts and cuts down on subsequent assembly operations.

Specifications and maintenance of high-speed injection molding machine

Specifications

• Materials: Speed injection molding machines can produce plastic parts using various materials such as PP, PS, ABS, PE, PET, and more. The choice of material depends on the specific requirements of the molded product.
• Clamping force range: High-speed injection molding machines come with different clamping force ranges. The clamping force of the machine is proportional to the weight of the die. Typically, the clamping forces range from 500 kg to 20 tons or more to accommodate various product weights and mold sizes.
• Shot size: It indicates the maximum amount of plastic the machine can inject in a single cycle. It is usually measured in grams and depends on the size of the injection unit's cylinder. Depending on the size of the injection unit, it can range from 50 g to 3000 g.
• Cycle time: High-speed injection molding machines typically have cycle times between 1 and 5 seconds depending on the complexity of the mold, the pressure applied to the material, and the material’s cooling time.
• Machine dimensions: These machines' sizes (length, width, and height) depend on the design and capacity. High-speed injection machines are usually more compact than standard machines.

Maintenance

• Daily maintenance:
• Water and oil pumps should be filled up to the prescribed level.
• Clean the molds, material containers, and injection nozzles thoroughly.
• Lubricate the moving parts of the machine to prevent friction and wear.
• Clean and inspect air and water filters to ensure good circulation and cooling.
• Check the temperature and pressure of each heating and injection section and adjust them as needed to ensure that they work within the normal range.
• Check the tightness of the mold clamping mechanism and adjust the appropriate clamping force as needed to ensure that the molds will not move or be loose during injection.
• Weekly maintenance:
• Clean the material conveying system components, including the conveyor belts, hoists, and pipelines.
• Inspect and clean water-cooled molds to avoid any clogging or cooling efficiency reduction.
• Inspect and adjust the alignment of the injection mechanisms to ensure they work properly and smoothly.
• Inspect the electrical connections and circuits to ensure that the wires and terminals are not loose or damaged.
• Inspect the mechanical components' wear and tear, such as guide rails, bearings, and gears. Lubricate or replace them as needed to ensure stable and accurate moving actions.
• Monthly maintenance:
• Cleaning the air and water pipelines throughout the system to prevent clogging and impurities.
• Lubricating the clamping mechanism and injection mechanism's guide rails, gears, and bearings.
• Adjust the cooling water flow of the mold and the temperature of the cooling system to ensure the stable operation of the equipment.
• Detailed inspection of electrical systems, including control cabinets, contactors, relays, etc., and cleaning and adjusting them as needed.
• Inspect the wear of high-speed injection molds and ensure that their cooling and heating systems work properly.
• Maintenance for oil pumps and hydraulic cylinders, including oil change and filter cleaning.

Uses of high-speed injection molding machines

• Mass production of plastic parts:

  High-speed injection molding machines are transforming raw materials into plastic parts at an impressive speed. Thanks to their rapid injection and cooling capabilities, they are ideal for producing large quantities of parts quickly and efficiently. This makes them a popular choice in industries where mass production of identical plastic parts is necessary, such as the automotive, consumer goods, and electronics sectors.

• Thin-walled product manufacturing:

  High-speed injection molding machines excel at producing thin-walled products. Their high injection speeds enable them to inject molten plastic into molds quickly, resulting in products with thin walls. This capability is particularly beneficial in industries such as packaging, where lightweight and thin-walled products are in high demand.

• Insert molding applications:

  High-speed injection molding machines play a crucial role in insert molding applications. They efficiently incorporate pre-placed inserts, such as metal components or electronic parts, into molded plastic products. The rapid production cycles of these machines enhance the efficiency of insert molding processes, which find widespread application in industries that require intricate combinations of plastic and other materials.

• Multi-material/multi-color molding:

  High-speed injection molding machines enable the rapid production of multi-material and multi-color molded parts. Their efficient material changeovers and rapid injection techniques allow for the quick injection of differentplastic materials. This capability is valuable in industries that demand complex parts with multiple colors or materials, such as automotive, consumer products, and medical device manufacturing.

• Precision molding operations:

  High-speed injection molding machines are suitable for precision molding operations. Their precise control systems and rapid production cycles ensure that high-speed molded parts meet tight tolerances and high-quality standards. These machines are indispensable in industries where precision is critical and high-speed production efficiency is desired, including the electronics, medical, and automotive sectors.

How to choose a high speed injection moulding machine

When selecting a high speed injection moulding machine, various factors need to be considered, such as production requirements, machine specifications, auxiliary equipment, energy efficiency, control system, safety features, and brand and after-sales support.

• Production requirements

  It's essential to identify business needs, such as the type of materials, product complexity, desired production volume, and the time to achieve the target. Consider the required precision and capacity to determine whether a high-speed injection moulding machine is necessary for specific production.

• Machine specifications

  When selecting a high-speed injection moulding machine, pay attention to its key parameters. The injection volume and clamping force should match the business production needs. Consider the machine's design and build quality, including the stability of the frame, airtightness of the clamping mechanism, heat manifold, and high-quality steel materials.

• Auxiliary equipment

  The combination of high-speed injection moulding machines and auxiliary equipment can improve production efficiency and product quality. Consider compatibility and coordination with the selected high-speed injection moulding machine.

• Energy efficiency

  Selecting an energy-efficient high-speed injection moulding machine can reduce operating costs and environmental impact. Choose a machine with a high energy-utilization rate and low power consumption.

• Control system

  The control system of a high-speed injection moulding machine directly impacts the accuracy and reliability of the injection process. Consider the flexibility and scalability of the control system so that it can be further developed and upgraded as required.

• Safety features

  High-speed injection moulding machines usually have some safety features, such as emergency stops, safety guards, and overload protection. These safety features help prevent accidents and ensure safe operation.

• Brand and after-sales support

  It's crucial to choose a reputable manufacturer that offers high-speed injection moulding machines. Consider the quality of the machine and the brand's after-sales support. This ensures timely repairs and maintenance services when needed. Conduct thorough research and comparison to select a reliable supplier.

High speed injection moulding machine Q&A

Q: How fast is an injection mold?

A: The speed of injection molding depends on several factors. It could take a few seconds to a few minutes to complete one cycle. Machines with smaller molds like high-speed injection molding machines for caps and thin-walled products have a cycle time of about 5 to 15 seconds. Large and complicated molds could take a few minutes to several hours.

Q: How many shots is an injection moulding machine good for?

A: Depending on the type of material used, the mold could take between 50,000 to a million shots before it starts showing signs of wear.

Q: What material is used for injection molds?

A: Materials like aluminum and steel are commonly used to make injection moulds. Steel is often the preferred choice as it is more robust and offers greater durability. Heavy-duty moulds for long production runs use stainless steel, while carbon steel is used for temporary or less complicated moulds. Aluminum is more affordable than steel. It is ideal for making injection moulds for small production runs and prototypes.

Q: What types of plastics are used in high-speed injection moulding?

A: Many types of plastics materials are suitable for injection moulding. These include thermoplastics like PVC, PP, polystyrene, ABS, polyester, and polycarbonate. High-speed injection moulding machines can work with various materials, including biodegradable plastics such as PLA, which are eco-friendly options for sustainable manufacturing.