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100213: Injection Molding
Injection Molding


 
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Availability:: Usually Ships in 8 to 18 Weeks
Product Code: 100213

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Email: sales@produstrial.com
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Fax: (973) 300-5477
Mail: 5 Larkspur Lane, Fredon, NJ 07860 USA

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Description
 

Details

            Injection molding makes use of the heat-softening characteristic of the thermoplastic materials. These materials soften when heated and reharden when cooled. No chemical change takes place when the material is heated or cooled, the change being entirely physical. For this reason the softening and rehardening cycle can be repeated any number of times.
      The granular molding material is loaded into a hopper, from which it is metered to a heating cylinder by a feeding device. The exact amount of material is delivered to the cylinder that is required to fill the mold completely. The injection ram pushes this material into the heating cylinder and in so doing pushes a like amount of heated material out the other end of the cylinder through the nozzle and sprue bushing and into the cavities of the closed mold. The material is cooled to a rigid state in the mold. The mold is then opened and the pieces are ejected.
      The temperature to which the material is raised in the heating cylinder is usually between 350 and 525 F. The higher the temperature, the lower the viscosity of the material, and the more readily it can be pushed into the die. Every type of material has a characteristic molding temperature. The softer formulations, those with higher plasticizer content, require lower temperature; the harder formulations require higher temperatures. Intricate pieces, large pieces, several cavities in the die, and long runners all tend to increase the temperature requirements. The cylinder temperature within the moldable range generally affects the physical properties of the finished molded article.
      When the plastic material is pushed from the nozzle end of the cylinder, it enters through channels into the closed mold. In the majority of cases the mold is kept cold in order to cool the molded articles rapidly to the point at which the mold can be opened and the pieces ejected without distortion. This is done by circulating water through the mold frame. Sometimes it is necessary to use a warm mold, and mold temperatures as high as 240 F are used for very special jobs. However, the material sets faster in a cold die, and the cycles are shorter. Automatic devices are commercially available to maintain mold temperatures at desired levels.

Advantages and Limitations. Since speed is one of the main advantages in injection molding, complicated molds with inserts should be avoided when possible. Injection molds need not be single-cavity, but the higher rate of production reduces the need for a large number of cavities. The savings resulting from higher production rates are partially offset by higher capital expenditure for machines and higher operating costs.
Injection molding is generally limited to forming thermoplastic materials, but equipment is "available for converting the machines for molding thermosetting plastics and compounds of rubber. The size of the article that can be molded is determined by the pressure and heating cylinder capacities of the machine.[1]



Price

Tooling and Sample Product This is a one-time charge for the custom tooling.  A few Free Sample Products are included in the price.   

Price each Based on part size, quantity and material.  Average labor costs range from $1 to $5 per hour.  Material costs are significantly less than market prices. 
Shipping Cost of shipping the product from the factory to your door. Most of our plastic molded products originate from Shanghai, China.
UPS Air Discounted rates apply. Each package must be less than 150 pounds (70 kg) and less than 108" long (270 cm). more details...
Fedex Air Discounted rates apply. Each package must be less than 150 pounds (70 kg) and less than 119" long (302cm).
+ Air plus Truck For shipments larger than UPS or Fedex restrictions. Quote upon request.
+ Ocean plus Truck Most economical, any weight or size. Minimum charge approximately $750. Best for heavy shipments that can wait the extra time. Extra increase in weight has smaller effect on cost.


Delivery

 Metric Drawing  Approximately 1 - 5 days after receipt of your order and tooling payment, our engineers will create a metric drawing for your review.
Tooling and Free Sample Products  Approximately 30 to 45 days after metric drawing approval, tooling will be made and a few sample products will be sent to you at no charge for your inspection and approval. 
Free Online Part Review  Please carefully inspect the parts and compare them with your requirements.  The production run of your parts will be the same as the samples so please indicate any changes at this time.  The best way to indicate revisions is to annotate them on a digital picture.  You may do this yourself and email them to info@produstrial.com or we can upload pictures to our secure collaboration website for Free Online Part Review.  If major changes are necessary, a second sample will be provided at no charge.

Production Approximately 30 to 45 days after the sample is approved products will be completed.
Shipping Air UPS Approximately 1 to 5 days
Air Fedex Approximately 1 to 5 days
+ Air plus Truck 3 to 14 days. For shipments larger than UPS or Fedex Air.
+Ocean plus Truck Approximately 30 to 40 days


Money Saving Tips

Get it in complete Combine our low cost machining, finishing, assembly and packaging service for a product that is boxed and ready for shipment.  Labor rates for this service average $1 to $5 per hour.
Consolidate Shipments We will hold multiple orders and ship them together to save freight costs.    
Ship by Ocean plus truck + This is the most economical shipping method for large and / or heavy shipments. 
Design in Metric When combining our services for a finished product, metric fasteners, hardware, o-rings, etc are less expensive and more readily available in China. 


Payment Terms

Tooling and Sample Product  This is prepaid before the samples and tooling are made.
50% of balance  This payment is due after the samples are approved.  Production will start after receipt of this payment.
Balance  Due when parts are complete and within 2 days of entering USA.  Net 30 terms for this payment may be extended for customers with established credit.

Payment Types

Credit Card  This is the preferred method of payment and will have the least impact on your delivery time.  We accept Visa, Mastercard, American Express and Discover Card.
Wire Transfer  This is a direct deposit to our bank and is recommended for international customers.    
Company Check  May delay your shipment for up to 2 weeks per payment.

How to Receive a Quote


This product is custom manufactured to your specifications and cannot be ordered online. You may, however,use one of the following methods to receive a quote:

Request Online: Choose your options, add to cart and proceed to checkout. There is no charge for this service, therefore, no credit card is required. You will receive an automated e-mail confirming your "Order" for a quote.

E-mail a request for quote to sales@produstrial.com. If appropriate, attach a sketch, drawing or picture.
Below please find the formats we can open:

Autocad : *.dwg
PDF : *.pdf
Drawing Interchange Format : *.dxf
Word: *.doc
Tagged Image File Format: *.tiff
Bitmap: *.bmp
Microsoft XPS document: *.xps
JPEG : *.jpg

Upload to our secure server.
Fax a request for quote to (973) 300-5477. If appropriate, attach a sketch, drawing or picture.

Call (973) 300-1344 and an application engineer will assist you.

Mail Prints and requests to: Produstrial , 5 Larkspur Lane, Fredon, NJ 07860

1. References: Tool Engineers Handbook

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