In broadest terms, the injection molding process can be broken into three steps:
1. PRODUCT DESIGN
Determining product objectives such as function, aesthetics, assembly, etc., and the requirements for accomplishing the objectives. A team of engineers specially trained in advanced methodologies such as Design for Manufacturability (DfM) is assembled to identify and possibly improve upon solutions to meet the particular project requirements — including the selection of materials for the final complex injection molded part and the tool.
2. TOOL DESIGN
Like product design, a thoughtful approach to tooling proves valuable. In addition to choosing the appropriate material for tool construction — hardened steel, pre-hardened steel, or aluminum — designing for proper gate location, draft, etc., is necessary to prevent costly project missteps.
Production is the obvious goal of the step-by-step injection molding process. Achieving successful outcomes brings together the product and tool designs with resins that deliver to project needs (such as strength, heat tolerances, sterility, etc.) and moldability requirements including tight tolerances, uniform wall thickness, heating, cooling, and consistent repeatable cycling.
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