What is high-precision plastic injection molding?
When it comes to plastic injection molding, it is important to have a clear definition in mind.
Therefore, high-precision plastic injection molding can produce components with tolerances as strict as 0.01 millimeters. In order to achieve such a result, the entire process is carefully controlled, from mold design to material selection and machine operation.
With this type of procedure, the main goal is to obtain accurate pieces with materials displaying low shrinkage rates. Thanks to this feature, the size of the parts is exact, and even the most intricate details can be replicated.
To ensure product quality at all times, high-precision plastic injection molding is performed using automated machines that, thanks to multi-axis control and accurate dosing system, can carry out real-time monitoring for delivering consistent quality outputs.
How does it work?
What are the key phases to ensure the creation of dimensional accurate high-precision injection molding?
Let’s discover how the process is performed.
- First, it is crucial to choose a design which can deliver perfectly smooth surface finish. At Idea Stampi, we always discuss the aesthetics and functional features of the mold with our customers to meet their expectations. In this co-design part of the process, we choose the most suitable material to execute high-precision injection molding flawlessly.
- Once we have customized the mold based on the customers’ requests, it is time to start designing the mold. Thanks to advanced technologies (CAD/CAM/CAE software), Idea Stampi’s skilled technicians can guarantee the utmost quality of every high-precision plastic injection molding project. Furthermore, using the VISI Flow simulation system, it is possible to craft the component and perform several test to outline the performance of the mold throughout time, optimizing the parts that are not working properly.
- The manufacturing phase is crucial, as the operator set up the parameters for the production of the high-precision plastic injection molds, such as pressure, melt temperature, and mold temperature. This configuration must be done impeccably because it could compromise production.
- The plastic material previously selected is injected into the mold cavity. High pressure is maintained through the course of the process in order to reduce every possible shift that could prevent the cavity to be properly filled.
- Once the mold it is filled, it is time for the plastic material to cool and solidify. At the end of the procedure, high-precision injection molding plastic parts are thoroughly inspected to ensure that all dimensional specifications are met.
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High-precision plastic injection molding applications
High-precision plastic injection molding presents a wide range of applications, spanning multiple industries.
The medical field
This technique is particularly useful for manufacturing high-precision plastic components for diagnostic devices and surgical tools. Moreover, at Idea Stampi we are also specialized in multi-imprint molds and dental accessories for the orthodontic sector.
The key to accomplish excellent large-scale pieces for this specific industry is accuracy.
The automotive field
Regarding the automotive sector, high-precision plastic injection molding allows manufacturing fans, pump bodies, plugs and other parts which are relevant in the production of cars. Strength and safety are key ingredients for a vehicle which, however, should be also light and fast.
Along with the automotive industry, the electromechanical field uses the properties of high-performance materials for the construction of technical parts. Aesthetics and precision are core features of these components, emphasizing once again the versatility and reliability of plastic for high-precision injection molding.
The electric field
High-precision plastic injection molding can be applied to the electric sector as well. The manufacturing of detailed small and medium-sized products to insert in more complex electric systems demonstrates the flexibility of plastic, which is perfect for this industry due to its tolerance to heat and other external factors.
Learn more about the Idea Stampi production of high-precision molds for multiple applications.
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What are the materials you can perform high-precision plastic injection molding with?
High-precision injection molding relies heavily on materials with certain characteristics.
Here you have a comprehensive range of all the most commonly used polymers implied in the process.
Amorphous Polymers
This material does not have a defined crystalline structure. Among amorphous polymers, we encompass:
- Polymethylmethacrylate (PMMA) is an acrylic with excellent optical clarity.
- Polycarbonate (PC) is renowned for its high resistance to impacts and dimensional stability.
- Polysulfone (PSU) is a performing polymer which can withstand heat and chemical resistance.
Semi-Crystalline Polymers
Semi-crystalline polymers comprise:
- Polybutylene Terephthalate (PBT) is an incredible material if you are interested in mechanical strength, dimensional stability and chemical resistance.
- Polyacetal (POM) is a low-friction and extremely resistant to wear material, commonly used to manufacture gears, bearings and mechanical parts.
Engineering Resins
This is a specialized category of thermoplastics that can contribute to the final output of your high-precision molding. Key examples include:
- Polyetherimide (PEI) which is extremely superior as for heat resistance.
- Polyether Ether Ketone (PEEK) can withstand high temperature, featuring high levels of mechanical and chemical strength.
Idea Stampi advanced technologies to perform high-precision plastic injection molding
At Idea Stampi high-precision plastic injection molding is carried out thanks to advanced technology and skilled professionals.
Our machinery includes:
- Computer-aided design (CAD) and manufacturing (CAM) systems: with the help of these tools, we can manufacture consistent and accurate components.
- High-precision plastic injection molding innovative machines to produce an output as close as it could be to the initial idea, regardless of the design intricacies.
Furthermore, our team of qualified experts is always trained to constantly integrate all these systems in order to create multi-cavity molds for high production rates for a number of applications, making Idea Stampi a reliable partner for your projects.
Each component has its own characteristics in terms of design and functionality. This is why at Idea Stampi we carefully analyze the type of plastic which can best suit the technical specifications of our customers to ensure the utmost accuracy, durability, strength and flexibility.
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