AS - Graphics - Injection Moulding

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AS-Level ­ Graphics ­ Injection
Injection moulding is the manufacturing process that I will be focusing on. It is used for producing
parts from both thermoplastic and thermosetting plastic.
Injection moulding works on the plastic being fed into a heated barrel where it is then mixed and
forced into a mould where it is left to cool where it will take up the shape of the mould.
The moulds that make the product are usually made out of metal such as aluminium or steel.
Injection Moulding is mostly used for making a wide range of parts from small things such as pens to
the side panels of cars.
Process characteristics
Utilizes a ram or screw-type plunger to force molten plastic material into a mold cavity
Produces a solid or open-ended shape that has conformed to the contour of the mold
Uses thermoplastic or thermoset materials
Produces a parting line, sprue, and gate marks
Ejector pin marks are usually present
What can it be used for?
Injection moulding can be used to create many things such as wire spools, packaging, bottle caps,
combs and most things made with plastic used today. injection moulding is the most commonly used
method for manufacturing small parts and/or parts.
Advantages are that there are high production rates, repeatable high tolerances, the ability to use a
wide range of materials, low labour cost, minimal scrap losses, and little need to finish parts after
Disadvantages are that the process are expensive equipment investment, potentially high running
costs, and the need to design mouldable parts.
Polymers of all kinds can be used including thermoplastics, some
thermosets and some elastomers.
Equipment used:
Made By Richard Francis -

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Injection moulding machines consist of a material hopper, an injection ram or screw-type plunger,
and a heating unit. They are also known as presses, they hold the moulds in which the components
are shaped. Presses are rated by tonnage, which expresses the amount of clamping force that the
machine can exert.…read more

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Injection-compression molding
Insert and outsert molding
Lamellar (microlayer) injection molding
Low-pressure injection molding
Metal injection molding
Microinjection molding
Microcellular molding
Multicomponent injection molding
Multiple live-feed injection molding
Powder injection molding
Push-Pull injection molding
Reaction injection molding
Resin transfer molding
Structural foam injection molding
Structural reaction injection molding
Thin-wall molding
Vibration gas injection molding
Water assisted injection molding
Rubber injection
Injection molding of liquid silicone rubber
Made By Richard Francis -…read more

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Molding Defects:
Blister - Raised or layered zone on surface of the part
Burn marks - Black or brown burnt areas on the part located at furthest points from gate or where air
is trapped
Flow marks - Directionally "off tone" wavy lines or patterns
Voids - Empty space within part (Air pocket)
Weld line - Discolored line where two flow fronts meet
Warping - Distorted part
Metal inserts can also be injection moulded into the work piece.…read more


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