Plastic injection molding is an extremely versatile method of producing plastic parts and has multiple advantages over other methods of plastic molding. Not only is the process simpler and more reliable than others methods, but it is also extremely efficient. Let's take a look at the top six advantages of this process:
1. High Efficiency- Fast Production
There are several good reasons that plastic injection molding is known as the most common and most efficient form of molding. The process itself is extremely fast compared to other methods, and the high production output rate makes it even more efficient and cost-effective. Speed depends on the complexity and size of the mold but only about 15-120 seconds pass between each cycle time.
With the short period between cycles, a greater quantity of molds can be produced in a limited amount of time, thus increasing possible revenue and profit margins. At Rodon, we run parts 24/7 using an MRP system (Material Requirement Planning System). While the MRP system can’t replace the input and experience of manufacturing managers, it does help improve efficiencies within the factory and this, in turn, creates savings for the customer.
2. Complex Part Design
Injection molding can handle extremely complex parts, and uniformity, as well as the ability to make millions of virtually identical parts. To optimize the effectiveness of high-volume injection molding and maximize the precision and quality of your parts, key design elements should be taken into account. The part design must be developed to maximize the efficiency inherent in high-volume molding. With the right design, parts can be made consistently and with quality. Without a good design, costly processing mistakes can be made.
Around the industry, most molding professionals agree that there are fundamental design elements that must occur during the injection process to work correctly. They include wall thickness, rib design, boss design, corner transitions and weld lines and gate placement, and properly placed vents. You can learn more about all of these elements here.
3. Enhanced Strength
Strength is one of the key factors that need to be determined when designing a plastic injection molded part. The designer will need to know if the part needs to be flexible or rigid so that he/she can adjust the integrating ribs or gussets. Understanding how the customer will be using the part and what type of environment the part will be exposed to is also important.
Finding the proper balance of design considerations will help address your part’s need for strength and stability. Material selection plays another key role in the strength of the part. See below for more information on the types of resins used in the process.
4. Flexibility- Material and Color
Choosing the right material and color for a project are two of the essential factors in creating plastic parts. Due to the wide variety of both, the possibilities are almost endless. The advances in polymers over the years have contributed to the development of a large selection of resins from which to choose. It is important to work with an injection molder that has experience with a variety of resins and applications including resins that are compliant with FDA, RoHS, REACH and NSF. To ensure you select the right resin for your project, keep in mind the following variables: impact strength, tensile strength, a flexural modulus of elasticity, heat deflection and water absorption.
Plastics can be colored using various coloring systems, each of which offers its own unique properties, benefits, and drawbacks. Masterbatches,”salt and pepper” blends, Liquid Color, and precolored resins are four of the most common coloring techniques. To learn more, check out our recent article on how plastic resins get their color.
5. Reduced Waste
When looking for a high-volume injection molding partner, it’s important to consider companies’ green manufacturing initiatives, as these signify a commitment to quality, sustainability, and optimal safety. During the molding process, excess plastic is generated. You want to look for a company that has a system in place to recycle its excess plastic. The most eco-friendly plastic injection molding companies employ state-of-the-art machinery to assist them in minimizing waste, transportation, and packaging.
At The Rodon Group, we’re committed to nurturing an ethos of environmental sustainability in everything we do. Over the years, we’ve instituted many green initiatives, all of which have helped us become one of the most sustainable leaders in the injection molding industry. Visit our Sustainability page to learn more about these initiatives.
6. Low Labor Costs
Labor costs are typically relatively low in plastic injection molding, in comparison with other types of molding. The ability to produce the parts at a very high level with a high output rate helps with its cost efficiency and effectiveness.
The molding equipment typically runs with a self-gating, automatic tool to keep operations streamlined and production ongoing, requiring minimal supervision.
Automation abounds at Rodon, from our 3D computerized design capability and automated tool fabrication processes to our computerized and automated plastic injection molding machines and robots. The entire Rodon facility is setup to produce the highest quality most economical plastic injection molded components in the industry.