News

Home >

China Shenzhen Perfect Precision Product Co., Ltd. company news

Should you repair or replace your injection mold?

Injection molding is one of the most commonly used manufacturing processes for mass production of plastic parts. Once you have perfected the mold for your part, it can make thousands to millions of pieces before going through the injection mold repair process. Creating custom molds can be expensive, so you want to make sure you invest in high-quality molds to maximize your profit and time. However, no mold lasts forever, and one day you will have to repair or replace it.

2023

06/16

Mold classification

The Plastics Industry Association (SPI), now known as the Plastics Industry Association (PIA), classifies molds according to the number of cycles they are expected to run. These classifications indicate the quality of the mold but are not a guarantee of quality as other factors can affect the life of the mold. You may see these referred to as SPI or PIA classes. Class 101 - These molds have been manufactured in over a million cycles - with extremely high yields. These molds are the most expensive and are manufactured with the highest quality materials. Tool structural parts must have a hardness of 28 Rc and the cavity and core must have a minimum hardness of 48 Rc. Areas that move relative to each other should have a hardness difference of at least 4 Rc. Other mold details such as heels, wedges, wedges and slides should be made of hardened tool steel. There are additional requirements for ejection, sliding, temperature control and parting line locks. Grade 102 – These molds are capable of up to 1 million cycles – medium to high production. The material hardness requirements of tool structural parts, cavity and core are the same as that of grade 10. Other functional parts shall be made of heat-treated steel. The most notable difference between grade 101 and grade 102 is that, depending on the expected part count, sliding wear plates, guided ejectors, corrosion-resistant plating chambers, and temperature-controlled channels may not be required. Grade 103 - These dies have a maximum life of 500,000 cycles - Medium production. Formwork bases must have a minimum hardness of 8 Rc and cavities and cores must have a minimum hardness of 28 Rc. Class 104 - These molds are manufactured in 100,000 cycles or less - Low-volume molds. This mold works best with non-abrasive materials. Formwork and cavities can be made of mild steel or aluminum. Class 105 – These dies are intended to last no more than 500 shots and are typically used for a limited number of prototypes. They are built in the cheapest way possible and may use cast metal, epoxy, or other materials.

2023

06/16

How long can the injection mold be used?

Injection molding is a cost-effective way to bring your product ideas to life. However, it requires upfront tooling costs that can run into tens of thousands of dollars or more, depending on the complexity of the tooling and materials used. When making a substantial investment in your product, it is reasonable to ask, "How long will the injection mold last?" There are nostandard answers. Mold life varies with a number of factors including mold material, mold maker's process, polymer being molded, and care and maintenance. Mold life is not determined by the number of months or years of use but by the number of production cycles. Dies can last from a few hundred to over a million cycles.

2023

06/16

What are the mechanical properties of plastics?

The mechanical properties of plastic affect how it responds to different types of loads and conditions. Tensile strength at yield and elongation at break are two commonly used indicators of material properties. But choosing a material for your product goes beyond that, as deformation is not the result you want. Material data sheets are the starting point for selecting the appropriate plastic - they should not be used to determine your polymer or product design. These tables are provided by polymer suppliers and describe the properties of a particular material grade. However, relying solely on datasheets may not give you the results you expect. Performance results are based on accepted industry standard testing conducted under specific conditions (e.g. temperature, humidity, machine, speed, preconditioning) which may vary significantly from those your product will experience. You also have to consider material compatibility and how they will react with other materials used. For example, certain adhesives may cause some plastics to become brittle. There may also be some regulations that should be considered for materials acceptable for food or medical devices. Knowing that choosing a plastic is more important than looking at a datasheet, we'll look at some of the mechanical properties that can be found on it. While there is no standard for data sheets, tensile strength, elastic modulus, and elongation are important mechanical properties to consider when designing a product.

2023

06/16

Tensile Strength of Plastics and Product Design

The push for lighter, stronger products, using less material and being more environmentally friendly has many companies looking for new materials or new ways to manufacture their products. But switching to new materials is not easy, and engineers must understand how polymers react under specific conditions. Hasty material selection can result in product failure or worse. Proper planning, a solid understanding of plastic materials and prototyping are required. Start by defining the mechanical, thermal, environmental, electrical and chemical requirements of your application. Polymers are then evaluated against these requirements. Below we discuss some mechanical properties that may be important to your application. The tensile strength and other mechanical properties of polymers allow engineers to understand strength properties that are critical to many products.

2023

06/16

What is ultrasonic welding?

One of the most common types of plastic welding, ultrasonic welding uses mechanical vibrations with high frequency and low amplitude to join two plastics. The vibrations cause frictional heat, which melts the material together, creating a molecular bond. Ultrasonic welding is fast, cost-effective, easily automated, and well-suited for mass production, making it one of the most popular plastic welding choices. With production rates of up to 60 parts per minute, this is likely the best choice for your operation. However, you should consider a few limitations of ultrasonic welding before choosing this process. It’s not suitable for thermoplastics with high moisture content and hard/strong thermoplastics like polypropylene. It’s also only best to create joints that overlap each other with this process. Corner, butt, tee, and edge joints likely won’t work well.

2023

06/16

what is laser welding?

As the name suggests, laser welding uses a laser beam to melt the plastic — keeping it below the evaporation temperature. Pressure is then applied to weld the two pieces together. It’s an extremely fast process and has a variety of options to choose from: contour, simultaneous, and hybrid. Contour laser welding is similar to traditional welding; the laser makes a single pass over the joint. During this pass, the plastic softens, melts, and fuses together. Because it’s limited to heating one single point along the weld line, it takes longer than some other methods. Simultaneous laser welding heats the entire joint at the same time, making it faster than contour laser welding. It often makes use of multiple lasers to speed up the process. Hybrid laser welding is similar to contour welding. It adds a high-powered halogen lamp to help the laser make a faster, more efficient cycle. The heat from the lamp helps improve laser travel speed and helps alleviate stress on the material. This process is typically used for large, free-form parts. Overall, laser welding allows for high-quality welds and fast throughput. However, it requires extremely tight tolerance parts to execute a great weld. Because the spot size after laser focusing is small and the weld is narrow, it’s susceptible to welding defects when the workpiece assembly or beam positioning is off.

2023

06/16

what is vibration welding?

Vibration welding involves rubbing the plastic part at a certain frequency and amplitude, creating heat and — ultimately — a weld. This sounds similar to ultrasonic welding, but the two processes are unique. The vibration welding process vibrates one component against the other in a linear side-to-side motion. Conversely, the ultrasonic welding process vibrates one component perpendicularly to another. Vibration welding and ultrasonic welding also use different frequencies when joining plastic. The vibration welding process uses 120-240 Hz and will depend on the size of the parts being welded. Ultrasonic welding uses much higher frequencies, typically 20,000-40,000 Hz (20kHz). The amplitude of the two processes is also different. Vibration welding typically uses between 0.4mm and 4.0mm, while ultrasonic welding uses between 0.025 or 0.125mm. Lastly, the welding time for each of these processes is slightly different. Vibration welding has a typical cycle time within the five to 10-second range, while ultrasonic welding is completed between one and three seconds.

2023

06/16

PLASTIC WELDING: HOW DOES IT WORK?

Plastic welding involves creating a molecular bond between two compatible thermoplastics. This bond is much stronger than other plastic joining processes — like adhesives and riveting. As such, it’s a common manufacturing process used throughout a variety of industries. Here, we’ll break down the specifics of plastic welding and help you determine if it’s right for your business.

2023

06/16

WHAT IS THE STRONGEST PLASTIC FOR INJECTION MOLDING?

There are a vast number of different plastics available for injection molding purposes, each with its own unique properties and characteristics. It’s nearly impossible to have an exact count because new plastics are constantly being developed, and plastics can be combined to take advantage of specific characteristics of each, and additives can be used, such as glass fibers, to improve strength and rigidity. If you are looking for the strongest plastic for injection molding, keep in mind that the strongest plastic for injection molding may not have all the properties your project needs, and you may find that a combination of polymers or the use of fillers or additives may provide an optimal solution.

2023

06/16

87 88 89 90 91 92 93 94 95 96

Shenzhen Perfect Precision Product Co., Ltd.

products

CNC Turning Parts

CNC Milling Parts

CNC Turning Milling Parts

CNC Machined Aluminum Parts

CNC Stainless Steel Parts

Machining Plastic Parts

CNC Brass Parts

lyn@7-swords.com 86-189-26459278

Building 49, Fumin Industrial Park, Pinghu village, Pinghu town, Longgang District, Shenzhen City, Guangdong Province, China

Quick links

Company Profile Factory Tour Quality Control News Sitemap Privacy Policy