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Are you looking for a low-cost manufacturer who will design and produce high-quality, tailor-made plastic products for you through plastic injection molding? Look no further, Karma Product Development provides the best injection services in Miami, FL.

Karma Product Development: Leaders in Plastic Injection Molding Services in Miami

Plastic injection molding or metal injection molding is a formative mass manufacturing process for making parts by solidifying molten material into the desired shape by injecting it into a mold. The solidified mold is then ejected and the process is repeated again.

Injection molding is mostly used for the manufacture of plastic parts which, depending on the machine, can vary in shape, complexity, and application.

Creative design

Most of the consumer products people use and many engineering applications are manufactured using injection molding. Injection blow molding is used to produce thin-walled plastic parts that are used as plastic housings which require many ribs and bosses on the interior.

Injection molding is used for the production of a variety of products such as

  •       household appliances,
  •       consumer electronics,
  •       power tools
  •       dashboards
  •       buckets
  •       toothbrushes
  •       plastic toys
  •       valves
  •       medical syringes

A host of materials are used for the molding technique including metals, plastics, glasses, elastomers, etc. The most commonly used ones are thermoplastic and thermosetting polymers.

Injection molding is different from additive technology such as 3D printing and subtractive tech like CNC machining. It is widely used in manufacturing as the process produces high volumes of output at affordable costs. The injection molding cost for 1,000 to 100,000 units will be around $1 to $5 per unit which is something you need to consider when seeking services of a plastic molding company.

The initial cost for the whole manufacturing setup is costly due to the custom injection molding. The time period to take the initial design to the factory floor is also long. Factors that affect the initial investment are

  •       complexity of the mold,
  •       the material to be molded (aluminum, steel, or plastic)
  •       purpose of the mold, whether it is for a prototype, or a pilot-run, or for the final product delivery.

Anywhere around $3,000 to $100,000 can be the initial investment for anyone who wishes to invest in a plastic molding company.

All thermoplastics are compatible with injection molding. Liquid silicones are thermosetting polymers compatible with the molding process.

This is a list of the most commonly used materials.

  •       Polypropylene (PP)
  •       ABS
  •       Polyethylene (PE)
  •       Polystyrene
  •       Polyvinyl Chloride – Plasticised
  •       Polyphenylene Oxide
  •       Polyamide 11+12 (Nylon)
  •       Cellulose Acetate
  •       Acrylic
  •       Acetal

Plastic injection molding with the first four materials amounts to 40% of all plastic parts produced in the world.

Karma Product Development has garnered an immense reputation in Miami, FL as the best in providing custom plastic injection molding solutions. Our experts have years of experience in molding all types of materials into consumer goods and electronic equipment for all types of purposes.

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How Does Karma Product Development Work?

The Injector Unit: The injector unit is used to melt the plastic polymer that comes in pellets before it is injected into the mold. As seen in the diagram, it consists of a:

Hopper: In the hopper, the pellets are mixed with an additive such as fibers, rubber particles, minerals, or flame-retardant agents in the ratio of 10%, 15%, or 30%  to increase stiffness, color, and other physical properties of the final product as desired.

Barrel: The material then moves into the barrel that contains the screw.

Screw: The screw pushes the pellets towards the mold while also compressing them. The movement of the screw produces 60% to 90% of the heat required to melt the plastic pellets. There are heater bands around the barrel to provide the rest of the heat. The melted material is then pushed into the cavity of the mold by the screw which acts as a plunger of a syringe.

The Mold: A mold is a hollow metal block designed into a particular shape. The raw material is injected into it and kept till it takes the shape of the mold. The mold has many holes through which air, water, or oil flow which keep the temperature at a certain level.

The mold consists of two parts, the cavity, and the core.

The Cavity: The cavity, which is called the A-side, forms the front half of the mold which is also the visual element or the cosmetic side of the mold. It is smooth and textured according to the design specifications.

The Core: The core, or the B-side of the mold, is the hidden functional component of the mold. It is closer to the injection system and contains all the structural elements of the part such as the bosses, ribs, snap-fits, and so on.

The melted material moves into the mold through a structure called the runner system. The runner system consists of three parts:

The Sprue: The sprue is the channel through which the melted plastic flows into the mold.

The Runners: One or more runners spread the melted plastic on the surface formed by the two parts of the mold meeting and connect the spur to the gates. The runner system is cut off from the final material after it is ejected. This is the waste material and 15-30% if it can be recycled and reused. Anything higher than 30% of the reprocessed material can spoil the raw material. Sometimes there is a vestige – the surface where the runner was connected with the part – left over after solidification.

The Gates: This is the entry point through which material flows into the cavity. Its geometry and location determine how the material will flow into the cavity.  Different types of gates are used for different applications. The four types of gates used in injection molding are:

  •       Edge gates
  •       Tunnel gates
  •       Post gates
  •       Hot tips

Straight-pull molds are usually used as they are simple to design and manufacture. For more complex shapes, side-action cores are used. These are moving elements that enter the mold from the top or bottom and are used to manufacture parts with overhangs.

The molds have cooling channels to aid in the solidification process and vents to evacuate air from the mold. About 50% of the mold is for the cooling and solidification of the material. Minimizing the thickness is most important for decreasing the cost of production.

The Clamping and the Ejection System

On the far side of the injection machine is the clamping system. This system keeps the two parts of the mold tightly shut during the procedure and once the part is ready it pushes it out of the mold

The alignment of all these different moving parts is never completely in line with each other. Hence imperfections can be seen on almost all parts made from injection machines. The imperfections can be seen along the parting lines at the point of contact of the two parts of the mold. They are also created by the ejector marks that slightly protrude above or below the surface of the mold.

The Injection Molding Process

Due to the advancements made in the industry, the injection molding process takes about anywhere between 2 seconds and 2 minutes. The process has the following steps.

Clamping: Before the material can be injected into the mold, each half of the mold is first secured with the help of a clamping unit. The hydraulically powered clamping unit pushes the two parts together with sufficient force to keep them pressed against each other while the material is injected between them. The time required to clamp the mold depends on the machine.

Injection: The raw plastic material is fed into the machine in the form of plastic pellets. The injector unit pushes the material into the mold quickly building pressure and heat that melts the pellets. The amount of material injected into the mold is called a shot. The time it takes for the injection depends on the shot volume, injection pressure, and power.

Cooling: The material is given time to cool off as it sets into the shape of the mold. Since shrinkage might occur during this process, additional material is allowed to flow inside to make up for it. The cooling time depends on the thermodynamic property of the plastic and the wall thickness of the part.

Ejection: The cooled part is ejected from the mold by the ejection system, attached to the rear end of the machine. A mechanism pushes out the part after the mold opens. Since the part might stick to the mold after shrinkage force applied to remove the part. Usually, a mold release agent is sprayed on the cavity before the material is injected. The time required to open the mold and eject the part is estimated from the dry cycle time of the machine. Once the part is ejected the mold is clamped shut again and the next cycle begins with the raw material being injected again.

Post-processing: Post-processing is the final step before the parts are dispensed on a conveyor belt. The process mostly involves trimming any excess material, called the flash, formed in the channels of the mold as strips. For some type of material such as plastic, the trimmed material can be recycled and reused. The thermoplastic flash is put through grinders called regrind machines or granulators which makes it into pellets again. Since the material has gone through material degradation during the heating and cooling process, it is mixed with raw material in a regrind ratio and reused.

Calculating an Injection Molding Cycle

Cycle = Mo+Mc+I+C

This is the formula for calculating a typical molding cycle where

Mc = Time taken to close the mold

I = Time taken to inject material into the mold

C = Time taken for the mold to cool down

To = Time taken to open a mold and eject the part

Benefits and Limitations of Injection Molding

Like any other manufacturing process that is constantly being upgraded over generations, custom injection molding has its own benefits and limitations.

Benefits of Injection Molding

Manufacture of large numbers: Competition in the manufacture of plastic products is higher than in any other industry. Hence it is important to produce a high volume of products in a limited time to be ahead of the competition. Custom injection molding helps achieve this target. The minimum number of units that a plastic molding company has to produce to make profitable returns on the high initial costs is 500.

Diverse range in raw materials: All thermoplastics and some thermosets and silicones can be used for custom injection molding. This makes the final products high in quality too. The wide range of raw materials is compatible with additives to achieve a wide range of physical properties.

High productivity: Unlike 3D printing or CNC machining which take hours to produce a unit, custom injection molding can create a part for every 60 seconds, depending on the material and complexity of the part. A single mold can also accommodate multiple parts, a mark of its high production capabilities.

High reproducibility: Every final part that comes out of the mold is identical to the other thousands of parts. The molds are usually CNC machined from aluminum which can produce 1,000 to 5,000 units or tool steel which can produce 100,000 and more units. For low-cost manufacturing units that have less than 100 parts, the molds can even be 3D printed.

Limitations of Injection Molding

High initial investment: The major concern for setting up an injection blow molding is its high cost of tooling. This is because of the custom mold that needs to be made for each design.

Changes to design are costly: Costs involved for modification of the mold are also costly. Usually preparing a new mold from scratch is considered less expensive.

High turnaround time: The turnaround time for custom injection molding can be around 6 to 10 weeks, where 4 to 6 weeks go into constructing the mold and 2 to 4 weeks for production and shipping. A 3D printer can be delivered overnight and CNC machined parts are delivered within 10 days.

Injection Molding in Present Economy

According to a global market analysis report, the global injection molded plastics market size was valued at $258.2 billion in 2019 and is expected to grow at a compound annual growth rate (CAGR) of 5% from 2020 to 2027.

The revenue forecast for 2027 for this industry is $374 billion. In 2019, Asia Pacific accounted for the largest revenue share of more than 35% for injection molded plastics.

This is due to the growing demand for plastic parts in various industries such as automotive, home appliances, packaging, electrical and electronic products, and medical applications.

But the injection molding costs are prone to changes in the price of raw materials such as benzene, ethylene, propylene, and styrene not to mention the growing global concern about the usage of plastic derivatives.

Our Services in Custom Plastic Injection Molding

As the plastic molding company near me, Karma Product Development leaves no stone unturned to produce superior quality plastic products through injection blow molding that suits any and all types of business needs.

Here is a look at all the types of injection blow molding services that Karma Product Development offers to all its clients:

  • In-house design and production of all types of products
  • Mold fabrication and production
  • Highly innovative designs with industry-wise injection molding costs
  • Manufacture of plastic products that follow client’s needs to the last detail
  • Industry compliant standards, 24/7 services, and access to knowledge experts.

Contact Karma Product Development at +1 (877) 650-8890 for more details right now. Our team will be happy to brief you on the wide range of cost-effective and high-quality custom injection molding services.

FAQs on Custom Injection Molding

How do I know if injection molding is the right process for my product?

When buying an injection mold, attention to detail all through the process is essential to long haul achievement and hassle-free assembling. Injection Molding is an extraordinary procedure for a massive scale finished production, but on the other hand it’s helpful for models that are utilized in beginning product design or for product testing by customers. The prospects and applications for using injection molding to deliver plastic parts are endless. Here are a few reasons why Plastic Injection Molding might be the correct decision for your product.

  • High Production Rates are Feasible.
  • Easy to complicated parts can be made
  • Varied choices of material selection
  • High accuracy tolerances can be kept up
  • Low work costs
  • Negligible scrap loss
  • Metal substitution

What type of resin/material is required for your part?

There are many part configuration factors that help decide the best material that will drive the expense, capacity, flexibility and creation of your parts. Having a fundamental comprehension of materials accessible and how they respond to the environment when your part will be uncovered can help give you an initial reference point. Your injection molder should offer detailed clarification of the materials or resins that best suit the unique necessities and cost prerequisites for your production part.

What type of information is required for quoting a molding project?

When looking for a quote from Karma Product Development, you can expect the following:

  • Services include Mold Making and Parts Production, which are further broken down into design and manufacturing. You need to choose a specific service depending on the prototype, design, or relocation of your part.
  • Industry Requirements come second. Depending on the industrial application of the part you’re getting injection molded, you can limit your options for working with a manufacturer.
  • The CAD design files of a prototype or an existing mold, the parts, and everything relevant to the project should be accessible. If you don’t have one, you can present drawings or photos.
  • The no. of parts to be made and its time-span is required.
  • Some other information includes whether you want to manufacture locally or transfer the product overseas. Tool Relocation, the type of plastic you want to use etc.

Karma Product Development considers all these aspects when asked for a quote. While these are the basic questions, most manufacturers also delve deep into the details depending upon specific requirements. There’s no hard and fast rule for every manufacturer.

How long does it take to build an injection mold?

Karma Product Development evaluates your product design and modifies it to injection mold it efficiently. Later, we proceed with building the mold for the part. Next, we put your mold into the injection molding press to produce production parts. On an average, the complete injection molding process may consume upto 8-10 weeks depending on the mold complexity and cavitation.

How much does it cost for injection molding?

Tooling comprises the most essential and the majority of the costs related to the injection molding process. As the procedure is the foundation of molding and having a successful production run, the complete cost heavily on the same. Pricing also depends on factors like complexities of the part, length of the production cycle, thermoplastic resin material selection, etc.

Some other details we consider while pricing involves the quantity of resin needed to create each part. The size of the part associates with the size of the injection molding machines, which are appraised by tonnage, or the measure of power expected to hold the mold closed. Injection molding machines’ process duration can increase depending upon the details of the part. These variables all have an influence on the expenses related to plastic injection molding.

Why Choose Injection Molding? 

In most production runs the molding cycle produces parts that are almost at their final stage. This implies that except if the part needs extra finishing touches, like painting, the assembling process is done, and the part can be bundled up and dispatched. This is an enormous cost-effective measure as multi-step fabricating cycles are mostly on the expensive side. The production cycle is moderately short, meaning that the parts possess a quick turnaround time for proceeding forward with the manufacturing process. Plastic Injection Molding is quite possibly the most cost-efficient and effective for producing a large volume of parts.

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