Injection moulding is a manufacturing process for producing parts by injecting molten material into a mould, or mold. Injection moulding can be performed with a host of materials mainly including metals, glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and injected into a mould cavity, where it cools and hardens to the configuration of the cavity. After a product is designed, usually by an industrial designer or an engineer, moulds are made by a mould-maker from metal, usually either steel or aluminium, and precision-machined to form the features of the desired part. Injection moulding is widely used for manufacturing a variety of parts, from the smallest components to entire body panels of cars. Advances in 3D printing technology, using photopolymers that do not melt during the injection moulding of some lower-temperature thermoplastics, can be used for some simple injection moulds.
A moldmaker or molder is a skilled tradesperson who fabricates molds for use in casting metal products.
Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or "film" when referring to thinner gauges and certain material types, is heated in an oven to a high-enough temperature that permits it to be stretched into or onto a mold and cooled to a finished shape. Its simplified version is vacuum forming.
Rotational molding involves a heated mold which is filled with a charge or shot weight of material. It is then slowly rotated, causing the softened material to disperse and stick to the walls of the mold forming a hollow part. In order to form an even thickness throughout the part, the mold rotates at all times during the heating phase, and then continues to rotate during the cooling phase to avoid sagging or deformation. The process was applied to plastics in the 1950s but in the early years was little used because it was a slow process restricted to a small number of plastics. Over time, improvements in process control and developments with plastic powders have resulted in increased use.
Berry Global, Inc is a Fortune 500 global manufacturer and marketer of plastic packaging products. Headquartered in Evansville, Indiana, it has over 265+ facilities across the globe and more than 46,000+ employees,including supporting manufacturing in Russia with an injection molding site in Yekaterinburg, Russia. With $13 billion in revenues in fiscal year 2018, the company is the 6th largest Indiana headquartered company in Fortune Magazine’s ranking. In April 2017, the company changed its name from Berry Plastics to Berry Global, Inc.
Flash, also known as flashing, is excess material attached to a molded, forged, or cast product, which must usually be removed. This is typically caused by leakage of the material between the two surfaces of a mold or between the base material and the mold in the case of overmolding.
An injection molding machine, also known as an injection press, is a machine for manufacturing plastic products by the injection molding process. It consists of two main parts, an injection unit and a clamping unit.
The Bemis Manufacturing Company is an American manufacturing company based in Sheboygan Falls, Wisconsin, and is best known for its toilet seat products. Bemis also manufactures plastic lawn, commercial, and indoor furniture, suction canisters, sharps containers, fluid management systems, gas caps, gauges and various contracted extrusion and injection molded plastic parts for companies such as John Deere and Whirlpool Corporation. The company is a pioneer of co-injection molding, a process in which virgin resin is injected with scrap plastic.
Chen Hsong Holdings Limited is a manufacturer and supplier of plastic injection moulding equipment and systems. The company was established by Dr. Chiang Chen in a small village workshop in Hong Kong in 1958. The following half-century has been a period of growth and expansion both locally and internationally. Today Chen Hsong has a customer base covering more than 80 countries worldwide including China, Taiwan, the United States, Canada, France, the United Kingdom, Brazil, Argentina, Mexico and most Southeast Asian countries.
Gemini Group, Inc. is a supplier of engineered plastic and metal products to OEM's and Tier 1 suppliers. The company operates internationally from its headquarters in Bad Axe, Michigan in the United States.
SRG Global Inc. is one of the largest manufacturers of chrome plated plastic parts for the automotive and commercial truck industries. Headquartered near Detroit in Troy, Michigan, the Tier 1 supplier has manufacturing operations across North America, Europe and Asia. The company’s Advanced Development Center in Taylor, Michigan, is a dedicated facility for developing new plastics coating technology.
Merrick Machine Company is a U.S. manufacturer based out of Alda Nebraska that produces custom automated housing machinery, The Auto Dolly, and The Auto Dolly accessory products, Merrick Originals. Merrick Machine Co was the founding business under the parent name of Triad, which now includes five other companies, all owned by the Merrick family. These companies are structured as limited partnerships and include Triad Fastener, Denver Plastics Nebraska, Merrick Machine Company, Fu-Tek Tool, and Triad Products. Each business is a stand-alone company doing business in separate facilities with independent offices, manufacturing, and warehousing.
Thin wall injection molding is a specialized form of conventional injection molding that focuses on mass-producing plastic parts that are thin and light so that material cost savings can be made and cycle times can be as short as possible. Shorter cycle times means higher productivity and lower costs per part.
Solid Concepts, Inc. is a custom manufacturing company engaged in engineering, manufacturing, production, and prototyping. The company is headquartered in Valencia, California, in the Los Angeles County area, with six other facilities located around the United States. Solid Concepts is an additive manufacturing service provider as well as a major manufacturer of business products, aerospace, unmanned systems, medical equipment and devices, foundry cast patterns, industrial equipment and design, and transportation parts.
Protolabs is a company that provides rapid manufacturing of low-volume 3D printed, CNC-machined, sheet metal, and injection-molded custom parts for prototyping and short-run production. Markets like medical devices, electronics, appliances, automotive and consumer products use these parts. Protolabs' headquarters and manufacturing facilities are located in Maple Plain, Minnesota. The company also has manufacturing facilities in England, Germany, and Japan.
Core Molding Technologies, Inc. was founded in 1988 and now based in Columbus, Ohio. The company manufactures sheet molding compounds (SMC), and molds fiberglass reinforced plastics. It occupies over 1,000,000 square feet of manufacturing space and its main subsidiaries are in Matamoros, Mexico, Gaffney, South Carolina, and Cincinnati, Ohio. In 2011, Core Molding Technologies formed Core Specialty Composites, LLC.
UFP Technologies, Inc., founded in 1963 and based in Newburyport, Massachusetts, is a designer and custom manufacturer of components, sub-assemblies, products and packaging utilizing highly specialized foams, films, and plastics primarily for the medical market.
In molding, an undercut is an indentation or protrusion in a shape that will prevent its withdrawal from a one-piece mold.
Gas-assisted injection molding is a molding process where an inert gas is injected into the melted plastic pushing it further into the mold and resulting in hollow parts.
Cube mold technology is a molding process for the manufacture of plastics components. This molding process allows to manufacture circular parts. This technology was introduced by Foboha and Arburg.
