What are the Common Materials Used in Injection Moulding?

Injection moulding is a widely accepted manufacturing process for plastic products. The technology can produce a wide array of plastic parts and prototypes for various purposes. From soft, flexible plastic goods to dense, rigid parts, injection moulding proposes diverse tolerance levels suitable for a large section of modern requirements.

In injection moulding, thermoplastics of multiple physical and mechanical properties can be used. With the increasing demand for high-performance plastic components, injection moulding manufacturers in India are constantly refining the technology to provide better quality products with improved surface finish and extended durability.

There are more than hundreds of thermoplastic materials used for diverse purposes. Thermoplastics are always in great demand due to their high tolerance, increased longevity, and affordability. From food packaging and battery enclosures to automotive engine parts, the application of thermoplastic materials is observed in every sector.

As mentioned, thermoplastics are of various forms. However, a few of them are preferred extensively. We will learn about the popular thermoplastic materials used by injection moulding companies in Noida. Let’s begin.

Injection Moulding at a Glance!

The injection moulding technology works on the principle of melting thermoplastics and pouring them into moulds to provide the desired shape and structure. Once cured, the final product is extracted from the mould and sent for post-processing if required.

Most of the plastic products we use in our everyday lives are manufactured through injection moulding. The process involves the following steps as implemented by the injection moulding manufacturers in India:

• The chosen thermoplastic granules are melted.
• The molten thermoplastic liquid is then injected into the mould under high pressure.
• As the mould cavity fills up, it is allowed to cool down.
• The holding time depends on the type of thermoplastic.
• Once it cools and solidifies, the final product is ejected from the mould.
• Excess material is removed from the product and sent for post-processing.

Now, you have the finished product with excellent surface finish, superior dimension accuracy, and high tensile strength. Since the lead time is much less, injection moulding is preferred for mass production.

Popular Materials for Injection Moulding

For a plastic component manufacturer India, the most challenging aspect is material selection for injection moulding. With an extensive variety of thermoplastic polymers, choosing the right material is necessary to accomplish the desired results.

We have listed the most common thermoplastics preferred for injection moulding. These include:

• Nylon (Polyamide)- Nylon is one of the most versatile injection moulding materials that can be used for diverse purposes. It is a polyamide component with a silk-like texture. Hence, nylon is used to produce fabrics, electrical insulators, car tyres, slide bearings, etc because it is resistant to abrasions and has incredible elasticity. However, nylon melts easily. Nylon 6 and Nylon 66 are well-accepted.
• Polycarbonate (PC)- If you are looking for engineering-grade thermoplastic, polycarbonate is the ideal pick. It is a hard, transparent, heavy-duty thermoplastic that can withstand high temperatures. PC possess impressive impact and fracture resistance features. Injection moulding manufacturers in India, like Bindal Technopolymer Private Limited, use polycarbonate to produce Ceiling Fan parts.
• ABS (Acrylonitrile Butadiene Styrene)- ABS is a very popular thermoplastic used extensively in automotive parts, phone hardware, keyboards, and others. It is an engineering-grade material possessing extraordinary dimensional stability, impact resistance, and an electrical insulator. ABS is sturdy and hard to break, though lightweight. Therefore, it is generally used for commercial purposes. Additionally, ABS can resist high temperatures.
• Thermoplastic Polyurethane (TPU)- TPU is a soft and elastic thermoplastic with outstanding tensile strength. It is tough and flexible, enabling you to draw into any shape. The dimensional stability of TPU is impressive, making it resistant to daily tears. Keyboard protectors, inflatable rafts, footwear, medical devices, etc., are some of the products made from TPU.
• Polyethylene (PE)- Injection moulding manufacturers in India use two types of polyethylene- high-density (HDPE) and low-density (LDPE). HDPE is solid plastic with impressive resilience and is primarily used in manufacturing plastic bottles, toys, pipes, etc. It is moisture-resistant and possesses good stiffness. On the other hand, LDPE is soft and flexible. It is resistant to moisture and chemicals. LDPE is widely used to produce plastic bags, food packaging, playground slides, and others.
• Polypropylene (PP)- Polypropylene is a multipurpose thermoplastic used in manufacturing consumer products and industrial automotive. PP is resistant to glue. Therefore, to stick or join PP parts, welding is generally implemented. Apart from that, PP is also resistant to acids, bases, and fats. It makes up an ideal material for pallets, laboratory equipment, hinges, Tupperware, etc.
• Acrylic (PMMA)- Acrylic is a commonly used thermoplastic which is transparent, recyclable, impact and chemical-resistant. It is almost similar to glass and often used as a substitute for shatterproof glass. Additionally, acrylic can filter UV rays. Acrylic is used for smartphone screens, bumpers, glass lenses, windows, and others.
• Polystyrene (PS)- Polystyrene can be easily moulded and possesses impressive electrical properties. However, it is brittle and flammable. The various applications of PS include food packaging, cassette covers, toys, cutlery, etc.
• PEEK (Polyether Ether Ketone)- Apart from nylon, plastic mould manufacturers in Noida consider PEEK as another versatile thermoplastic used for multiple purposes. PEEK has numerous advantages like resistance to stress, abrasion, pressure, and chemicals and low emissions. It can be sterilized and so used for medical equipment, containers, tools, etc. Other uses of PEEK are compressors, heavy machine parts, tubes, valves, electrical cables, and pumps.
• Acetal Homopolymer- In injection moulding, acetal homopolymer is preferred for its excellent strength and stability. It is a tough and resilient plastic possessing enhanced stiffness and tensile strength. Acetal homopolymer is highly machinable and ideal for creating prototypes. It is broadly used to produce conveyor belts, gears, automotive cooling parts, etc.

To conclude, injection moulding being an immensely acknowledged plastic manufacturing process, it is implemented upon a wide array of thermoplastic polymers. From consumer products to heavy-performance industrial components, you can choose from a variety of thermoplastics.