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The primary molding process mainly used in the plastic industry is injection molding.
With the help of the injection molding machine and the influence of heat, the plastic material is brought to a viscous state.
Subsequently, the melt is injected under pressure into the cavity in the mold.
The shape and surface structure is determined by the geometry of the cavity.
Cooling or cross-linking reaction (for elastomers) solidifies the part and it can be ejected after opening the two mold halves.
The injection molding process is particularly suitable for large quantities.
This is due to the fact of high mold costs which need to be payed proportionally by the produced parts.
Injection molded parts can be used directly after ejection.
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A group of experts in the plastic industry founded the company PLEXPERT, 2006 in Germany, in order to save resources, providing a positive impact on budget and environment.
There are two divisions within the company. One is focusing on finite element simulations (FEM) like injection molding simulation and structural analysis.
Based on decades of practical experience DFM conform results are given by the consultant service of PLEXPERT to decrease part costs and increase quality in the production of plastic parts.
The second division is focused on the development and supply of soft- and hardware to the plastic industry. With the state of the art products PLEXPERT contributes to secure production and reduce the need of precious resources.
Today PLEXPERT has offices in Canada, Germany, Thailand and China in order to support its customers fast and effectively.
Due to a close network of plastic experts, partners are available in many other countries as well and offer PLEXPERT products and services.
PLEXPERT Company Logo.
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Since 2015, Moulding Expo has been a popular meeting place for the plastic industry.
The fair takes place every two years for four days in Stuttgart, Germany.
Tool, model and mold makers present themselves.
Additionally, systems and services for the plastic industry and metal processing are displayed.
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For the production of injection molded parts a mold is necessary to be placed on the injection molding machine.
It is commonly build out of steel or aluminum and is designed as a permanent form.
Depending on the plastic material used millions of parts can be created with one mold.
The complexity of a mold range from a simple two-plate molds up to a complex stack mold with sliders, etc.
To avoid additional costs it is important to think about the mold concept early in the concept phase of part design.
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"Parts, which have been produced from melt by non-cutting molding (e.g. by pressing, compression molding or injection molding) in all side closed molds" are referred
to as molded parts according to DIN 7708, sheet 1 [freely translated].
Thus in injection molding, the end product, which is produced by filling the cavity with molten plastic, is called a molded part.
It should be noted that a possibly existing cold runner is not a component of the molded part.
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Temperature plays the most important role if it comes to injection molding.
Before the part is ejected it is good practice to analyse the temperature distribution on the surface.
This is where IR-ThermalSystem comes into play.
It consists of an infrared camera, a magnetic stand, cables some electronic device and a specialized software (called IRDAS), that records
all the critical information from one shot to another.
The system used for quality control, supports a centralized database and can be connected to several other
products that are useful in the injection molding process.
This includes DiagBes as well as Xscale and Xmold.
Evaluating temperature helps to identify short shot and flashing as well as proper functionining of the cooling channels.
The International Exhibition on Plastics and Rubber industries in China, called Chinaplas, is an exhibition from the organizer Adsale.
In 1983, it opened the doors for the first time in Guangzhou (China).
Since 2006, it has been approved by UFI (The Global Association of the Exhibition Industry).
Chinaplas runs every year for four days and has a significant world wide influence on the plastics and rubber industries.
It is the biggest fair for this industry in Asia and is held in yearly turns in Guangzhou and Shanghai.
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The definition of quality according to DIN 55 350/T11 is "the nature of a unit as its suitability to meet specified and required needs".
Different factors are used to evaluate the quality of plastic parts.
The easiest is the optical evaluation.
Visible surfaces should not contain streaks, burn marks, sink marks and/ or air traps.
The dimensional examination is used to control the functionality of the part.
Shrinkage and Warpage are main quality criteria.
The technical drawing shows the necessary tolerances of the part for an acceptable quality.
Mechanical testings are necessary to check the different applied forces on the part dependent on its usage.
Fiber orientation, weld lines, voids and wall thickness may lead to this quality failure.
The choice of the material and the processing, both influence the mentioned quality factors decisively.
Injection molding simulation and additional structure analysis help to check the quality of a part in advance.
