Understanding Precision Injection Molding: A Comprehensive Guide

Tight Tolerance:

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The defining feature of precision injection molding is its ability to achieve exceptionally tight tolerances. Precision injection molding products adhere to tolerances as fine as 0.01mm to 0.1mm. This level of precision ensures that each part or component produced is almost identical, meeting even the most exacting specifications.

High Repetition Accuracy: 

Precision injection molding excels in producing parts with high repetition accuracy. Repetition accuracy refers to the consistency of dimensions and properties across multiple parts. In precision injection molding, product weight deviation is minimal, typically less than 0.7%. This means that each piece emerging from the mold closely matches the one before it. This level of consistency is crucial in industries where reliability and uniformity are paramount.

High-Quality Mold Materials: Molds used in precision injection molding are typically made from durable and heat-resistant materials such as steel or aluminum. These materials withstand the high temperatures and pressures involved in the molding process, ensuring longevity and consistency.

Precision Machining: Molds are created using advanced machining techniques, including CNC (Computer Numerical Control) machining. This precision ensures that the molds’ cavities and details are reproduced accurately, down to the finest tolerances.

Complex Geometries: Many products produced through precision injection molding feature intricate and complex designs. Molds are tailored to accommodate these intricate geometries, allowing for the precise replication of intricate parts and components.

High Cavity Dimensional Accuracy: Achieving high dimensional accuracy within the mold cavity is crucial. Every contour, every corner, and every detail must align precisely with the desired specifications.

Smooth Cavity Surfaces: The interior surfaces of the mold cavity must be exceptionally smooth. Smooth cavity surfaces ensure that the injected material flows evenly and without obstruction, resulting in defect-free products.

Precise Positioning Between Templates: In multi-cavity molds or molds with moving parts, precise positioning between templates is essential. This ensures that each part produced is consistent and free from defects.

The manufacturing process of precision injection molding is the same as that of traditional injection molding. The main processes include 6 stages. They are the preparation of raw materials, material melting, mold filling, cooling, mold opening, and post-processing. Click here to learn more about the injection molding process. The difference is that precision injection molding has higher requirements for mold design, materials, technical parameters, etc. Next, let’s take a look at the technical parameter requirements of precision injection molding during the production process.

First, the injection pressure must be greater than 25MPa;

Injection speed is greater than or equal to 300mm/s;

Product dimensional accuracy is 0.001mm;

The standard deviation coefficient (change rate) of product quality is less than 0.1%;

Mold opening and closing position accuracy: opening ≤ 0.03mm closing ≤ 0.01;

The injection position accuracy (pressure holding end point) is less than 0.03mm;

The force balance of the tie rod is less than 1%;

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Pre-molding position accuracy is less than 0.03mm;

Balance degree of fixed and movable platens A: less than 0.03mm when the clamping force is zero B: less than 0.005 mm when the clamping force is maximum;

The barrel and screw temperature: The temperature control accuracy of the barrel and screw is less than ±0.5℃.

Measuring accuracy: To maintain the high stability of plastic products, the amount of hot melt plastic injected into the mold cavity must be equal each time.

Mold temperature: The temperature change on the surface of the mold cavity should be controlled within ±1°C.

Precision injection molding stands out as a manufacturing process renowned for its multitude of advantages, each contributing to its significance in the manufacturing landscape.

Exceptional Accuracy: Tolerances as fine as 0.01mm to 0.1mm are routinely achieved. Each product mirrors the exact specifications of the master mold, ensuring uniformity and reliability.

Consistency: Whether producing one part or one million, precision injection molding maintains consistency. Each piece is virtually identical, free from defects, and meets stringent quality standards.

Cost-Efficiency in Large-Scale Production: The repeatability and efficiency of precision injection molding result in faster production cycles. This is especially advantageous when manufacturing high volumes of components.

Shrinkage: Materials used in precision injection molding should have low and predictable shrinkage rates. Material suppliers provide data on shrinkage rates for different materials, allowing mold designers to compensate for this effect during mold design.

Dimensional Stability: Materials should exhibit excellent dimensional stability, especially when exposed to temperature variations.

Strength: Depending on the application, materials may need to possess specific strength characteristics.

Rigidity: Rigidity refers to a material’s resistance to deformation under load. In some cases, parts must remain rigid to maintain precision, while in others, flexibility may be preferred.

Flexibility: Materials may need to exhibit a degree of flexibility to accommodate specific design requirements.

Surface Finish: Materials should be capable of producing a high-quality surface finish in the molded part.

In the world of manufacturing, precision is not just a goal; it’s the foundation upon which innovation and quality are built. Precision injection molding stands as a testament to this commitment to excellence. Throughout this post, we’ve delved into the intricacies of precision injection molding, uncovering its vital role in modern industry. Precision injection molding is more than a manufacturing method; it’s the embodiment of precision itself. It ensures that every component produced adheres to the strictest standards of quality, dimensional accuracy, and reliability.

Whether you require components for the medical field, automotive industry, electronics sector, or any other application demanding excellence, Zhongde is your precision injection molding partner of choice. Contact us today and let’s bring your precision molding needs to life.