Injection moulding is an advanced process used by industries today to manufacture detailed and complex plastic parts. And the injection moulding machines are making this process possible, moulding the molten materials into required shapes with high precision. This blog post describes the classification, types, and specific features of these moulding machines, helping one decide the best for their use.
Introduction to Injection Moulding Machines
Plastic injection moulding is quite crucial for the manufacturing of plastic parts. It is thus indispensable for industries like automotive, healthcare, consumer goods, and electronics. In this process, plastic resins undergo heating until they reach the melting stage. They are then injected into a mould, where they cool down and solidify in the desired shape. Current developments have created plastic injection moulding robots which simplify the process and ensure the same quality.
Classification of Injection Moulding Machines
Injection moulding machines can be classified on various bases, including mode of operation, design and intended use. The main types are:
On the basis of modes of operation:
- Hydraulic machines
- Electric machines
- Hybrid machines
On material compatibility
- Thermoplastic injection moulding machines
- Thermoset injection moulding machines
On application specialisation
- General-purpose machines
- Specialised machines
Each classification helps to define certain aspects such as capability, precision, and efficiency.
Types of Injection Moulding Machines
Injection moulding machines can be categorised based on different criteria:
1. By Drive System
Hydraulic Injection Moulding Machines: These traditional machines use hydraulic systems to generate the necessary pressure. They are known for their robustness and are suitable for producing large parts. However, they consume more energy and may require more maintenance.
Electric Injection Moulding Machines: Utilising electric servo motors, these machines offer high precision, energy efficiency, and faster cycle times. They are ideal for applications requiring cleanroom conditions, such as medical device manufacturing.
Hybrid Injection Moulding Machines: Combining the benefits of hydraulic and electric systems, hybrid machines offer improved energy efficiency and precision. They are versatile and suitable for a wide range of applications.
2. By Orientation
Horizontal Injection Moulding Machines: The most common type, where the mould opens and closes horizontally. They are suitable for high-volume production and are easier to operate and maintain.
Vertical Injection Moulding Machines: In these machines, the mold opens and closes vertically. They are ideal for insert moulding applications and occupy less floor space.
3. By Material Processed
Thermoplastic Injection Moulding Machines: Designed to process thermoplastic materials, which can be melted and remelted multiple times. They are widely used in various industries due to the recyclability of thermoplastics.
Thermosetting Injection Moulding Machines: These machines process thermosetting materials, which, once set, cannot be remelted. They are used for parts requiring high heat resistance and structural integrity.
Metal Injection Moulding (MIM) Machines: Specialised machines that process metal powders mixed with a binder, allowing for the production of complex metal parts with high precision.
4. By Specialisation
Multi-Material Injection Moulding Machines: Capable of injecting two or more materials into a single mould, allowing for the production of parts with multiple materials or colours.
Micro Injection Moulding Machines: Designed for producing extremely small and precise parts, commonly used in medical and electronic applications.
Liquid Silicone Rubber (LSR) Injection Moulding Machines: Specialised for processing liquid silicone rubber, suitable for producing flexible and heat-resistant parts.
Specialised Injection Moulding Machines
The latest developments in manufacturing, facilitated by technological advances, now allow access for manufacturers to a range of specialised machines catering to specific production needs.
- Multi-material Injection Moulding Machines: These machines can process two or more materials at once to manufacture a multi-coloured or multi-material part.
- Micro Injection Moulding Machines: These machines are great for the generation of really small and very precise parts, often within the areas of medicine and electronics.
- Vertical Injection Moulding Machines: This type has a vertical clamping unit and is perfect for insert moulding operations.
- All-Plastic Injection Moulding Machines: They are designed to produce fully plastic components free of any metallic or other material insert.
Key Features of Each Type of Injection Moulding Machine
- Hydraulic Machines
– High clamping force
– Cost-effective for bulk production
– Suitable for large parts
– Electric Machines - Energy-efficient
– Low noise and maintenance
– Superior precision - Hybrid Machines
– Combines power and efficiency
– Suitable for a wide range of applications - Thermoplastic Machines
– Reusability of material
– Versatility in part designs - Thermoset Machines
– Handles high-heat materials
– Durable and heat-resistant outputs - Specialised Machines
– Tailored for specific production requirements
– Enhances efficiency and innovation
Choosing the Right Injection Moulding Machine for Your Needs
Before you set out to examine choices for an injection moulding machine, do consider the following points:
- Know Your Material: Most thermoplastics or thermosets require specific machines.
- Set Production Scale: Hydraulic machines will work well with high production numbers while high specification jobs can be run using electric machines.
- Consider Automation: High-speed production is going to work better where you employ injection moulding robots for better accuracy and reduced cycle time.
- Future Prospects: Hybrid machines offer the flexibility to look into the future as an investment.
Bottom Line
Injection moulding machines are the core of modern manufacturing, offering a wide spectrum of solutions for the production of quality plastic components. From hydraulic conventional systems to plastic injection moulding robots, each machine is designed to tackle specific problems. In other words, for every automotive large part or small intricate medical device, there’s always an injection moulding machine available to be suited for one’s needs.