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Have you ever encountered such a situation where a set of molds were tried repeatedly, but they just couldn’t figure it out. These problems were changed, and other problems occurred, such as changing the gate position, changing the runner gate size, and modifying the product. To meet the molding requirements, repeated Bucket Mould Manufacturer trials are very wasteful. When the problem is serious, the mold cannot be modified and can only be scrapped. The mold needs to be redesigned and manufactured, which affects the delivery time. The above problems are common occurrences in mold factories. The fundamental problem is that the mold flow analysis (CAE) is not in place.

Mold flow analysis technology can simulate and evaluate the molding process of plastic parts on the computer before mold processing. If there is a problem with the design plan, the revised plan can be input into the system again for analysis until it is satisfied. Therefore, a good application of this technology can correctly design molds, reduce design and manufacturing costs, and improve product molding quality has a great effect.

(1): Mold flow analysis can know whether the product has filling problems. For example, whether the product has short shots, bubbles, and unbalanced filling during the injection process can be determined by carefully analyzing the filling curve. In the mold flow analysis, you can change the position of the injection mold gate, injection speed and other processing conditions, so that you can know whether these problems can be improved or corrected.

(2): Mold flow analysis can know whether the product is full. It can also provide other useful information such as the required maximum injection pressure and clamping pressure to provide a reference for us to choose an injection molding machine.

(3): Mold flow analysis can calculate the efficiency of the cooling circuit. Adding cooling analysis to deformation analysis can increase accuracy. Because the cooling water circuit is difficult to modify once it is completed, this type of analysis is very useful before opening the mold.

(4): Ability to predict whether the product is deformed. The absolute value of the deformation is predicted and analyzed, and the deformation prediction can be used to compare the gate position, wall thickness changes or design changes.

(5): It can be used to check and correct problematic mold prototypes. The problem in detecting injection molds is to use mold prototypes to do “short shots”. Mold flow analysis can determine which changes will be effective, faster and less expensive than mold repair.

We are a professional molding company, sell different design of mold, Pail Mould is one of them,welcome to visit our website.

One of the most important aspects of any product development project using Plastic Pail Moulding is choosing the right material, as it directly affects the molding operation and also the part performance. There are thousands of plastic materials available in the market. So, how do you make sure you select the right one?

When choosing a plastic, the first thing you have to consider is the part function and its environment. What material would be best suited for the part’s application? Then the material’s strength, durability, flexibility, color and cost come into play. To help you better understand this process, here is a list of some of the most common plastic molding materials and their applications.

Nylon (Polyamide)

Nylon is often used to produce strong mechanical parts. Bushings, gears and bearings are some common automotive parts produced using nylon. It is tough, and has a high melting temperature, good wear and chemical resistance. Nylon is also known by its chemical designation PA (Polyamide).

Acrylic

We use acrylic to produce transparent parts such as windows, transparent walls and various lighting equipment. It is often used as an alternative to glass due to its high tensile strength and weather and scratch resistant nature. On top of its optical and transparent properties, it also has many unique qualities. You would usually spot this material in refrigerators and containers to store food, as acrylic is odorless and tasteless and doesn’t contain Bisphenol A (BPA), a potentially harmful organic synthetic compound that’s not suitable for food preparation and storage.

Polycarbonate

Polycarbonate has excellent optical properties and is extremely durable. When molding with this amorphous thermoplastic material, precise dimensional control can be maintained as it has predictable and uniform mold shrinkage. We use polycarbonate when we need something substantially stronger than acrylic. This material is not suitable for food storage and preparation as it contains Bisphenol A (BPA).

Polyoxymethylene (POM)

Polyoxymethylene is a type of acetal resin used for producing mechanical and automotive parts that would usually be made with metal. This engineering thermoplastic material is very strong, tough and rigid. It is often used to produce gears, fasteners, knife handles and ball bearings. Although polyoxymethylene has high resistance towards solvents such as alcohols, gasoline, detergents and motor oils, it should not be exposed to hydrochloric acid and nitric acid.

Polystyrene (PS)

When it comes to injection molding, there are two types of polystyrene that are commonly used. High Impact Polystyrene (HIPS) and General Purpose Polystyrene (GPPS). General Purpose Polystyrene is transparent, while High Impact Polystyrene is opaque. Hard cases for toolboxes and bodies of power tools are also made using High Impact Polystyrene. While they are inexpensive, they are not environmentally friendly.

Acrylonitrile Butadiene Styrene (ABS)

This is an opaque thermoplastic polymer and an engineering grade plastic. There are many advantages to using Acrylonitrile Butadiene Styrene. It is tough, has good dimensional stability, high impact resistance and resistance to scratching, breaking and tearing. It has low melting temperature and is relatively inexpensive. It is commonly used to produce electronic parts such as phone adaptors, keyboard keys and wall socket plastic guards.

Polypropylene (PP)

This thermoplastic material is widely used in the food storage and packaging industry, as it does not let chemicals mix with food products. Polypropylene can be washed in hot water without degrading, and it has high chemical and moisture resistance. It has incredible impact strength, elasticity and toughness.

Polyethylene (PE)

Polyethylene is a lightweight thermoplastic material that has high chemical resistance, elasticity and electrical insulating properties. It is not especially strong or hard, but still, this material is used in wide variety of consumer plastic parts, such as milk bottles, medicine and detergent bottles, plastic bags and trash cans. Polyethylene is also the most common injection molding plastic type to be used in the production of children’s toys.

Thermoplastic Polyurethane (TPU)

Thermoplastic polyurethane, because of its soft and elastic nature and great tensile and tear strength, is often used to produce parts that demand a rubber- like elasticity. TPU performs well at high temperatures and is commonly used in power tools, cable insulations and sporting goods.

Thermoplastic Rubber (TPR)

This material is usually a mix of plastic and rubber, and is easy to use in the injection molding process. TPR exhibits properties of both rubber and plastic materials. It has outstanding chemical and weather resistance and high impact strength. You can find this recyclable material in medical catheters, suspension bushings and headphone cables. Thermoplastic rubber is also known as thermoplastic elastomer (TPE).

Full Injection Molding Material List

We hope this brief overview helped you to understand some of the most popular injection molding plastic types, their properties and applications. Please note that we can work with you to modify all of these materials with lubricants, glass fibers and UV stabilizers to suit your unique project needs.

Here, you can check out our full material list for plastic injection molding. You can also explore the most common injection molding defects and their solutions in our recent article. Ready to collaborate with us on your next manufacturing project? Request a free quote today!

We are a professional molding company, sell different design of mold, 20L Bucket Mould is one of them,welcome to visit our website.

If you have an innovative Bucket Mould product idea, chances are you probably need someone to help it come to life…

This is where product design firms come in.

These companies will help you turn your idea into a quality, cost effective design and get your product onto the market quickly. However, there are a lot of product design firms to choose from…

So how do you choose the right one?.

In our experience, there are three main things you need to do to ensure that you are picking the right firm for your innovation:

LOOK AT THEIR EXPERIENCE AND EXPERTISE

Their past works and background can tell you a lot about what they will be able to do for you.

The main thing you should be looking for is if the firm will fit your project. Seeing what they have done for others in the past can give you an idea of what they will be able to do for you and the standard of work they are able to produce.

Don’t just take their word for it either… seek out testimonials and reviews from their past customers to get an idea of their reputation and what will be in store for you.

MEET THE TEAM

Building trust with your design firm is an essential part of the manufacturing process so you will want to check that they seem like the real deal.

Before you choose, make sure to meet the team that will be developing your idea so that you know who you will be working with, their own personal specialities and the equipment they have access to within the firm.

Start with a phone call and work your way up to a visit to the workshop.

WHAT SERVICES DO THEY OFFER?

Is the firm only going to be able to make the product for you? Having a look into what services they are able to provide is crucial to setting your expectations.

You won’t want to have to switch firms halfway through the process because they don’t offer adequate design, prototyping or manufacturing.

At Rixiang Mould, we offer a range of comprehensive services in every step of the product design process. These include:

Product design, including concept assessment and project scoping

Prototyping and process and materials testing

Manufacturing, production, assembly and packaging

If you are struggling to choose a product design firm that is the right fit for you, have a chat with the team at Rixiang Mould.

We’ll work with you to ensure that your product is the best it can be and help you every step of the way.

We are a professional molding company, sell different design of mold, Pail Mould is one of them,welcome to visit our website.

With hundreds of commodity and engineering resins available on today’s market, the material selection process for Plastic Pail Mould injection may seem daunting at first.

ABS

Offering superior toughness, strength, impact resistance, and temperature resistance, acrylonitrile butadiene styrene (ABS) is used in a wide range of industries and applications, from automotive to piping. ABS combines the strength and rigidity of acrylonitrile and styrene polymers with the toughness of polybutadiene rubber. ABS is easily molded and provides a colorfast, glossy effect with a high-quality surface finish. This plastic polymer has no exact melting point.

ABS materials can be processed using any of the standard thermoplastic processing methods. It easily adheres to itself, similar plastics, and metal coatings, making it well-suited for a range of different products.

For instance, it’s frequently used in appliances, telephone handsets, computer and other office equipment housings. ABS can also be used in musical instruments, golf club heads, medical devices, lawn mower covers, motorcycle helmets, canoes, toys, enclosures for electronics and electronic assemblies, luggage, interior and exterior automobile trim, showerheads, and handles. When extruded into a filament, ABS is ideal for use in 3D printers.

ABS does not have good chemical resistance, however, and should not be used in applications requiring electrical insulation or UV resistance.

Celcon (Acetal)

Celcon is a common brand name for acetal, also known as polyoxymethylene (POM), polyacetal, or polyformaldehyde. This thermoplastic offers outstanding toughness, excellent wear, creep resistance and chemical solvent resistance, easy colorization, good heat distortion, and low moisture absorption. Celcon® also provides high stiffness and excellent dimensional stability.

Ideal for food and beverage, mechanical, automotive, and household applications, this is our resin of choice for manufacturing toy parts, as well as various gears and bearings. It works especially well for plastic gears, as it greatly minimizes the friction resulting from contact.

Celcon is frequently used in “point-of-contact” pieces, parts that physically touch another surface. Common point-of-contact pieces include those used on the bottom of couches to allow for smooth sliding across the floor, as well as guitar picks, pinch valves, and plastic buckles. This versatile thermoplastic is also used in bearings and bushings, pump and valve parts, manifolds, jigs and fixtures, wear pads, and electrical components.

It should not be used for applications in high-heat environments, however, and is subject to UV degradation.

Polypropylene

Polypropylene (PP) is one of the most widely produced plastics in the world. It’s known for its chemical resistance, elasticity and toughness, fatigue resistance, insulation properties, and transmissivity. Although flammable and vulnerable to UV radiation, polypropylene still offers good resistance to chemical solvents and electricity.

A diverse range of applications makes use of polypropylene, as it can be easily customized by introducing special additives or altering the manufacturing process. In fact, this versatile material is sometimes referred to as the “steel” of plastics since PP can be tailored to so many different uses.

Polypropylene is well-suited for applications within the packaging, electrical and equipment manufacturing, household appliance, automotive, and construction industries. More specifically, PP is used for packaging solutions, buckets and bowls, plastic parts, living hinges, toys, medical components, washing machine drums, bottle caps, and textiles, among many other items. Polypropylene has a relatively slippery surface, so it’s possible to use PP as a substitute for other plastics, like acetal, in low-friction applications, such as gears and furniture contact points. Most grades of polypropylene are flammable and subject to degradation by UV radiation.

HIPS

plastic injection molded tubes

High-impact polystyrene (HIPS) provides good impact resistance, excellent machinability, fine dimensional stability, outstanding aesthetic qualities, and highly customizable surfaces. HIPS can be printed, glued, bonded, and decorated easily. It’s also very cost-efficient.

High-impact polystyrene is used in many print applications, such as promotional signs, display materials, garden stakes and tags, posters, and retail packaging, as well as 3D lenticular or moving images. In fact, HIPS is specially formulated for use in graphic arts applications. HIPS is also ideally suited for high-speed digital printing equipment. Other common uses include appliance components, TV and audiovisual (AV) equipment parts, bicycle trailers, toys, gasoline tanks, hot and cold drinking cups, and computer housings.

Although HIPS is flammable, flame-retardant varieties are available.

LDPE

The most flexible type of polyethylene, low-density polyethylene (LDPE) offers superior moisture resistance, high-impact strength, good chemical resistance, and translucence. A low-cost option, LDPE is also weatherproof and can be easily processed with most methods.

Low-density polyethylene is used in a wide range of everyday products and applications. It can be found in many consumer goods and housewares, for example, as well as medical products, agricultural products, and electronic wiring. This versatile resin is found in shopping bags, plastic film and packaging, bottles and containers, lids and caps, six-pack rings, computer components, juice boxes, and toys. And with more and more people recycling bags and wraps, LDPE products often get a second life in items such as shipping envelopes, garbage can liners, floor tile, paneling, furniture, compost bins, trash cans, and landscape timber.

LDPE is difficult to bond, however, and should not be used in harsh weather or high-temperature applications.

We are a professional molding company, sell different design of mold, 20L Bucket Mould is one of them,welcome to visit our website.

There’s a lot of room for expensive errors when it comes to injection Plastic Pail Moulding. Quality issues in injection-molded products can range from minor surface defects to more serious problems that can affect the safety, performance and function of the product. They can be caused by problems related to the molding process, material use, tooling design or a combination of all three.

As an importer or manufacturer of injection-molded products, some knowledge of common molding defects and how to avoid them can help you cut costs related to unsellable goods and product returns.

Let’s look at the most common quality defects related to injection molding, what causes them and what you can do to prevent them.

MOLDING DEFECTS OFTEN CAUSED BY PROCESS PROBLEMS
Some molding defects may be difficult or costly to address. Others can be prevented by adjusting the molding process, without the need to redesign the mold tooling or replace other production equipment. You can typically avoid these defects relatively easily simply by adjusting the flow rate, temperature or pressure of your mold.

1. Flow lines
   Flow lines appear as a wavy pattern often of a slightly different color than the surrounding area and generally on narrower sections of the molded component. They may also appear as ring-shaped bands on a product’s surface near the entry points of the mold, or “gates”, which the molten material flows through. Flow marks won’t typically impact the integrity of the component. But they can be unsightly and may be unacceptable if found in certain consumer products, such as high-end sunglasses.

Causes and remedies for flow lines
Flow lines are most often the result of variations in the cooling speed of the material as it flows in different directions throughout the mold. Differences in wall thickness can also cause the material to cool at different rates, leaving behind flow lines.injection molding defects For example, molten plastic, cools very quickly during the injection process and flow marks are evident when the injection speed is too slow. The plastic becomes partially solid and gummy while still filling the mold, causing the wave pattern to appear.

Here are some common remedies for flow lines in injection-molded products:

Increase the injection speed, pressure and material temperature to ensure the material fills the mold before cooling
Round the corners of the mold where wall thickness increases to help keep flow rate consistent and prevent flow lines
Relocate mold gates to create more distance between them and the mold coolant to help prevent the material from cooling too early during flow
Increase the nozzle diameter to raise flow speed and prevent early cooling.
3. Warping
Warping is deformation that can occur in injection molded products when different parts of a component shrink unevenly. Just as wood can warp when it dries unevenly, plastic and other materials can warp during the cooling process when uneven shrinkage puts undue stress on different areas of the molded part. This undue stress results in bending or twisting of the finished part as it cools. This is evident in a part that’s meant to lie flat but leaves a gap when laid on a flat surface.

Causes and prevention of warping in molded parts
One of the main causes for warping in injection-molded plastic and similar materials is that cooling happens too quickly. injection molding defectsOften excessive temperature or low thermal conductivity of the molten material can worsen the problem. Other times mold design can contribute to warping when the walls of the mold are not of uniform thickness—shrinkage increases with wall thickness. Here are some common ways to prevent warping in your molded parts:

Ensure the cooling process is gradual and long enough to prevent uneven stresses on the material
Lower the temperature of the material or mold
Try switching to a material that shrinks less during cooling (e.g. particle-filled thermoplastics shrink much less than semi-crystalline materials or unfilled grades)
Redesign the mold with uniform wall thickness and part symmetry to ensure greater stability in the part during cooling.

We are a professional molding company, sell different design of mold, 18L Bucket Mould is one of them,welcome to visit our website.