Extensive Guide into Low Volume Plastic Molding
Low volume production plays an important role in plastic molding. It allows many plastic manufacturers to meet their ever-increasing customer demands. This is because of the quick turnaround in molding these plastic parts. However, the making of low volume plastic molding parts requires the use of different available manufacturing processes. For instance, at Creatingway we can use short-run injection molding to produce such parts. This also depends on the amount specified during the quotation.
Further Insight Into The Process of Low volume Plastic Molding
The Process of Low Volume Plastic Molding
The process begins by getting all the necessary tools needed to start the plastic injection molding process. We need to follow all steps accurately in order to get precisely finished products as described. First, we desiccate raw granules of plastic resin to the right moisture level. We could then mix with color shades at this step if quoted. Then we pour the dry resin granules into a casting machine bowl.
Inside the bowl is an alternating screw that moves the resin granules towards the mold’s direction. The next step involves heating and mixing if the solid particles inside the barrel. The temperature has to reach the melting point to convert the solid resin granules into the liquid resin. At the other end, the mold closes spontaneously after being heated. We then put the liquid resin under pressure, infusing it into the mold chamber through an opening. Cooling of the mold follows to harden the resin. Lastly, we remove the formed resin piece from the mold to begin a new series.
Modes of Low Volume Plastic Molding Parts
There exist four methods of low volume plastic molding. Having a good understanding of each method will help you decide which one suits you best.
Short Run Injection Molding
Short-run injection molding is also known as prototype injection molding. We use it in making injection molded pieces for prototypes, short runs, and bride tooling. The parts made are meant to be used as a single time runoff. However, is ideal for producing plastic part in a small volume.
Pressure forming is also known as thermoforming. The process involves using a hollow elongated tool and covering with a hot layer of liquid resin. First, we stretch the tool after passing the vacuum through the apparatus. Then, we apply pressure at the layer’s back, filling the chamber into the needed shape. Cooling soon follows forming a new plastic piece. We use a CNC cutting machine to remove excess material from the formed plastic part
Structural foaming begins with a short injection of plastic resin. We then blow into the resin to make the material larger inside the mold. This allows the resin to take the shape of the mold. However, the part has a hollow inside with a hard outer skin. This may affect the structural integrity of the part. Another issue is the occurrence of burst bubbles on the outside. We have the option of rectifying this occurrence either painting or sanding. Overall with structural foaming, it is less costly to get your parts ready.
Reaction Injection Molding
Reaction injection molding involves injecting a thermoset liquid plastic then later mixing at low pressures. The material has a dense and stiff structure with low cost and capable of doing a high number of shots. One good advantage is its surface finishing ability. We can easily achieve the right color order and do sanding for any cosmetic pieces. Therefore, it is the right low volume plastic molding parts with sophisticated detail.
Benefits of Low volume Plastic Molding
It satisfies the need for a few thousand parts to meet the demand for the pre-production and production run. This is before shifting into mass production.
Cheaper Mold Cost
We make the low volume molds from high-quality plastic grades. This lessens the cost as it is easy to machine and modify when compared to the metal molds.
Fast Turnaround to Market
To make the product, it only requires a modest investment. Hence, the product can reach much quicker to the market. Also, there is a lower loss in case the product is not a success.
Why Choose Low Volume Manufacturing
Less Investment Risk
You can easily correct the design of your product until it is ready for large scale production.
You get the added benefit of a quicker turnaround for producing your mold. This will get your products faster in the market.
When compared to large scale production, it is cheaper. It because the tooling cost is lesser to get the minimum orders.
Before considering the mass production of your product, it is important to us low volume production lessen the risk. Contact Creatingway now for your low volume plastic molding needs.
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