Sincere tech offers thin-wall injection mold/molding manufacturing, our company has been made some thin wall multiple cavity molds, such as Cosmetics injection molding twenty-four cavity mold, eight-six multiple cavity molds, etc. if you have a project that needs thin wall plastic mold/molding services, you have come to the right place, we will solve your issue here and make your project 100% successful.
Thin-wall injection molding rising in status as material costs continue to rise and delivery lead times as squeezed. Thin wall plastic molding provides the chance to decrease material part cost and to raise production output via quicker cycle times.
This trend is taking place in all kinds of injection molding industries such as packaging, automotive, medical, electronics, mobile communications, optical and computing tools.
To make thin wall injection molding is not easy, you cannot use the normal machine and process, you need to make precision mold and use high precision and high-speed injection molding machine,
Advantages of thin-wall injection molding parts
- Lower material cost per part
- Higher production output due to quick cycle times
- Low power cost per part due to quick cycle time with hydraulic machines
Reducing wall thickness is the key to making lighter parts and better production outputs. A thinner wall section permits shorter cooling time and cycle time.
Challenges of thin-wall injection molding
High capital investment
This thin wall molding needs injection molding machines that have the capability to produce high injection speeds, high injection forces, are repeatable and are rigid enough to be reliable for the long term. These machines are costly.
Similarly, the injection mold requires to be powerful enough to withstand high cavity forces, production rates, and clamp tonnages.
A perfect mold design should be considered since this thin wall injection mold will be running so fast, the cycle time sometimes will meet 4s, High-quality mold design and mold manufacturing will be the key point to success the thin wall molding, otherwise, the mold will be broken very soon.
The mold cooling system design must be optimized so that warm is extracted fast. Just having a thin wall on a part is not sufficient to get quick cycle times, below are some thin wall injection mold projects we made before. If you have a project ready to make thin wall mold or molding, contact us to get a price.
Steep learning curve
Thin wall plastic molding needs high technology molding machines that have a multitude of control functions. Learning about the machine and all of its works will permit you to get the most of out it.
What is more, process parameters play an important role in successful thin wall molding. To produce standard parts the process needs to be fine-tuned as the operating window for parameter settings is extremely narrow. Some parts need injection times of 0.1 second and any variation in this time will cause part standard issues such as short shots or flashing. Parts with thicker wall sections have a much bigger operating window and are simpler to mold.
Generally, robots are used to get rid of and stack parts in thin wall molding. This is mainly general in thin-wall food packaging containers. Medical injection molding, Cosmetics injection molding parts, etc. Learning how to use the robot rightly is another area that must be mastered. Because moulds of thin parts are made with extremely tight tolerance, mould maintenance needs to be performed daily. Any build-up of residue across the venting surfaces will outcome in parts standard problems mainly on multi-cavity molds.
Hot runner systems in thin-wall injection molding
When we make thin wall injection mold, basically we will make multiple cavity molds, maybe 4 cavities, 8 cavities or even 86 cavities, etc. To reach the short cycle time we need to use hot runner systems for the mold. Since it is multiple cavity mold and thin wall parts, we need to use high precision hot runner as well, to make sure that the injection filling status 95% balance for each cavity, if the filling is not balanced, some of the parts will have flash and some of the parts will have short shot.