A Complete Checklist for Injection Moulding

In the era of 3D printing, injection moulding is one of the fastest and most reliable techniques to produce high-quality plastic parts and prototypes. The speed and precision of injection moulding are remarkable, enabling designers and engineers to acquire seamless results within seconds to minutes! This manufacturing technology is extensively accepted across diverse sectors, including aerospace, automotive, food and packaging, electrical, and medical. Did we miss out on anything?

As is evident, almost every industry relies on injection moulding to produce premium-grade products at cost-effective prices. Nevertheless, even the most recognized injection moulding manufacturers in India encounter numerous challenges during the production process. As an injection moulder, the principal objective is to accomplish products with accurate dimensions, surface finishes, scalability, turnaround time, and costs.

It is not as simple as it may sound! The significant fact is every aspect of the manufacturing process relies on a set of variables. These variables or factors considerably affect the outcome. Therefore, plastic injection moulding manufacturers must be aware of them.

What are they? Let’s learn about them.

Vital Checklist for Injection Moulding

Being a highly affordable manufacturing technique for plastic products, injection moulding is used in large-scale production of numerous parts, prototypes, and end-use products. But, a plastic moulding company in Noida has to comply with the following checklist to achieve the desired results:

1. Categorization- As you know, in injection moulding, thermoplastic pellets are melted and forced into the mould at the required pressure and temperature. The liquid material attains the shape of the mould, and you finally receive the product as the mould cools. However, injection moulding is typically of four types:

• Overmoulding- Through overmoulding, you can produce plastic products with two different colours or materials. Generally, the production takes place in two phases.
• Insert Moulding- In this process, metal or other material is embedded within the plastic product. You will notice insert moulding mostly in electrical or mechanical components.
• Precision Moulding- Injection moulding manufacturers in India apply precision moulding when they require parts with superior dimension accuracy. It is a highly controlled process. Such products are used in the automotive and electrical industries.
• Micro Injection Moulding- When you manufacture finely detailed miniature parts, micro injection moulding is your ideal choice.

2. Choice of Material- Injection moulding is a versatile production technique using diverse thermoplastics. There are more than 200 thermoplastics! Apart from thermoplastics, there are elastomers like polyurethane, natural rubber, etc. and thermosetting plastics like nylon, PVC, etc. These thermoplastics are further classified according to their strength, durability, tolerance, and purpose. There are plastics like ABS, PVC, etc., for daily use products and high-performance plastics for enhanced strength and endurance like PEEK, LCP, etc. Also, you get engineered plastics like PA, PC, and others.

3. Required Tolerance- What is the product’s purpose? Plastic injection moulding manufacturers set the necessary tolerance relying on the product functionality. The tolerance level is pivotal in determining the dimensional accuracy of a product. The tolerance should never be too high or too low as it critically affects the product quality. As a result, the functionality of the product gets compromised.

4. Surface Finish- The aesthetics of a product matter depending on its usage. For example, external parts or visible products must possess a pleasant look compared to the internal parts. Complying with the standard aesthetic considerations is necessary to ensure a product meets the quality specifications. Therefore, surface finish is a crucial aspect that determines aesthetics, utility, and real feel. Textured surfaces exhibit fewer imperfections than high-gloss surfaces. However, polished surfaces offer a sleek look with a smooth, silky touch. On the other hand, textured surfaces have a grainy feeling, though visually appealing.

5. Volume- Production can be on a large scale or small scale. The higher the volume, the more the production time. Additionally, injection moulding manufacturers in India require advanced machines with increased mould cavities for large-scale production. Hence, the price of production of each part becomes less in high-volume production. However, in small-scale production, the cost of the mould is the predominant investment. So, manufacturers prioritize reducing the mould cost to curtail the overall production expenses.

6. Quality Check- In injection moulding, a quality check is performed at every stage. From mould design to post-processing, stringent quality standards are maintained everywhere to ensure optimal dimensional accuracy and surface finish. The quality check inspectors test each product individually using rigorous techniques to achieve the highest degree of quality standard. Undeniably, it enhances the efficiency, durability, and appearance of a specific product.

7. Post-Processing- Some products may require post-processing to deliver the necessary look and functional needs. Generally, post-processing techniques are of various types- welding (heat, friction, etc.), mechanical (drilling, milling, etc.), and surface coating (electroplating, painting, etc.).

8. Production Cost- Apart from the common materials used in injection moulding, surface finish, volume, and post-processing determine the cost of production. To curtail production costs, manufacturers often optimize mould and product design, minimize post-processing, and collaborate with other companies. The production cost ultimately affects the price of individual product pieces.

9. Packaging- The packaging of a product depends on multiple factors like shipping, single or complete product, size, and amount. Plastic bags are generally used for shipping products to prevent surface abrasion. Nonetheless, for single or bulk packaging, cardboard boxes are typically preferred.

Key Takeaways

Technological advancements have significantly revolutionized the injection moulding process. Today, innovative tools, robotic arms, and fully automated systems are used to increase productivity, enhance quality, and boost efficiency. We, Bindal Technopolymer Private Limited, are a premier plastic moulding company in Noida that serves diverse industries with high-quality plastic parts and products. Our specialized crew of design specialists, production engineers, and quality inspectors offer extraordinary solutions while meeting custom requirements. We propose comprehensive manufacturing support to small and large-scale industries at the best prices. So, collaborating with us means taking the initiative to embrace innovation!