Amid the booming modern industry, injection molded plastic precision component manufacturing plays a vital role, widely used in numerous fields, including electronics and automotive. However, production efficiency and quality control, two key factors, constantly impact manufacturing success. The following will delve into the factors influencing these factors and analyze corresponding countermeasures.
II. Factors Affecting Production Efficiency and Countermeasures
1. Raw Material Factors
1.1 Specific Manifestations Affecting Production Efficiency:
Poor raw material flowability: In some cases, increasing injection pressure by 30%-50% significantly increases the injection cycle time, for example, from an average of 30 seconds to 40-50 seconds.
Poor raw material stability: Poor adaptation to process parameters increases the probability of decomposition and discoloration by 20%-30%, requiring remolding, significantly wasting time and resources, and slowing production progress.
1.2 Countermeasures:
Establish a strict inspection system to monitor key indicators of incoming raw materials.
Establish long-term partnerships with quality suppliers to ensure a stable supply and reduce the risk of reduced production efficiency due to raw material issues.
2. Mold Factors
2.1 Specific Manifestations Affecting Production Efficiency:
Improper Parting Surfaces: Mold demolding is difficult, requiring an average of 2-3 minutes per demolding, significantly increasing the injection cycle time. Originally capable of 30 injection cycles per hour, this impacts the cycle time by reducing it to approximately 20.
Poor Cooling System: The probability of component defects such as deformation and warping can be as high as 40%-50%. To avoid these defects, cooling time often needs to be extended by 30%-50%, resulting in a longer overall injection cycle.
Inadequate Mold Manufacturing Precision or Wear: This can lead to molding defects in the component, requiring re-molding and hindering production efficiency.
2.2 Solutions:
Utilize advanced software technologies during the design phase to optimize the design, such as CAD and CAE, to assist in selecting parting surfaces and designing the cooling system.
Ensure strict precision control during manufacturing, employing high-precision machining processes.
Regular maintenance during use includes cleaning, lubrication, inspection for wear, and timely repair or replacement to ensure molds are in good condition.
3. Injection Molding Machine and Process Parameter Factors
3.1 Specific Manifestations Affecting Production Efficiency:
Insufficient injection volume: If the actual injection volume is 20%-30% less than the required volume, sufficient plastic cannot be injected into the mold cavity in one shot. Multiple injections may be required, increasing the injection cycle time from an average of 60 seconds to 90-120 seconds.
Insufficient injection pressure or clamping force on the injection molding machine: The probability of incomplete molding of parts is approximately 15%-20%, requiring remolding.
Improper process parameter settings: If the injection temperature is too low, the probability of incomplete molding of parts can reach 30%-40%. Excessive injection temperature not only affects part quality but also requires re-preparation of raw materials for injection molding. Improper settings for injection speed, holding time, and cooling time can also lead to part defects, requiring re-molding, which wastes time and resources.
3.2 Countermeasures:
Select an appropriate injection molding machine based on component requirements and perform regular maintenance and repairs.
Through extensive testing and accumulated experience, optimize process parameter settings to find the optimal combination that ensures quality while shortening injection molding cycles, thereby improving production efficiency.
III. Factors Affecting Quality Control and Countermeasures
1. Raw Material Quality Factors
1.1 Specific Manifestations Affecting Quality Control:
Low purity and impurities in raw materials: When the impurity content exceeds 0.1%, the probability of surface defects such as bubbles and scratches on the component surface can reach as high as 30%-40%.
Poor physical properties: This can easily lead to component damage during subsequent use. Poor chemical properties can shorten component lifespan by 30%-50% under certain chemical environments.
1.2 Countermeasures:
Establish a comprehensive inspection process and comprehensively test the physical, chemical, and mechanical properties of each batch of raw materials.
Resolutely avoid using substandard raw materials to ensure quality from the source.
Plastic Case for a physiotherapy hot compress spinal cervical support device
2. Mold Accuracy and Condition Factors
2.1 Specific Affecting Quality Control:
Mold accuracy and condition have a critical impact on component quality. For example, in the injection molding of a mobile phone case, if the mold dimensional accuracy deviation exceeds ±0.03mm, the dimensions of the molded part will deviate accordingly, failing to meet the precise design requirements, thus impacting subsequent assembly steps.
If the mold wears or deforms during use, the probability of component quality issues, such as surface roughness and warping, can be as high as 40%-60%.
2.2 Countermeasures:
After manufacturing, strictly inspect the mold for accuracy, and only use it if it passes the test.
Perform regular maintenance during use: clean, lubricate, inspect for wear, and promptly repair or replace the mold to ensure good mold condition and component quality.
3. Process Parameter Setting Factors
3.1 Specific Affecting Quality Control:
Process parameter setting is crucial. Excessively high injection temperatures can cause plastic decomposition and deterioration, affecting the intrinsic quality of the part. Excessive injection pressure can lead to flash and deformation. Improper holding and cooling times affect part dimensional accuracy, appearance, and performance.
3.2 Countermeasures:
Monitor process parameters in real time during injection molding and make timely adjustments if deviations are detected. Through extensive testing and accumulated experience, determine the appropriate parameter range to ensure part quality.
In the manufacture of precision
Plastic injection molded parts, production efficiency and quality control are affected by multiple factors. Issues related to raw materials, molds, and process parameters require careful attention and appropriate countermeasures to improve efficiency, ensure quality, and enhance a company's competitiveness in the industry.
3.500+ Material Choices Custom Injection Molding
