What is injection moulding?

Injection moulding is a manufacturing process that allows to produce a large amount of identical items in a short time. It is a cost-effective and efficient way to produce parts and products made of metal, glass and elastomers, although it is most commonly used with plastic (thermoplastic and thermosetting polymers, to be specific). In this blog post, we will explore what injection moulding is, how it works, and the advantages and drawbacks of this process.

What is injection moulding?

Injection moulding involves injecting molten material into a mould cavity. The material then cools and solidifies, taking the shape of the mould. This process is used to create a wide variety of parts and products. These can range from small components, like bottle caps, to large items such as automotive parts, chairs and storage containers. Injection moulding is especially useful when there is a need to manufacture many thousands, or even millions, of identical objects.

The injection moulding process

The injection moulding process begins with the creation of a mould. The mould is made from metal (usually aluminium or steel) and is designed to the exact specifications of the product to be manufactured. Once the mould is ready, raw materials are fed into the injection moulding machine. These materials are usually in the form of pellets.

Inside the machine, the pellets are heated until they melt. The liquid material is then injected into the mould cavity under high pressure. The mould is kept closed until the material has cooled and solidified. Once it has hardened, the mould is opened, and the newly-formed part is ejected.

What are the advantages of injection moulding?

Injection moulding provides several advantages over other manufacturing processes. These advantages include:

• Cost-effective: Injection moulding is a cost-effective way to mass-produce parts and products. The process is highly automated, which means that labour costs are reduced. Additionally, the high production rates mean that the cost per unit is lower.
• High precision: Injection moulding allows for high precision and accuracy when creating parts and products. This is because the mould is designed to the exact specifications of the product, and the process is highly controlled.
• Fast production: Injection moulding is a fast process, with high production rates. This means that large quantities of parts and products can be produced quickly and efficiently.
• Reduction of waste: Injection moulding produces low waste rates. Other manufacturing processes waste higher percentages of raw materials. Also, injection moulding commonly uses thermoplastics, and thermoplastic residues can be recycled. This further reduces waste.

What are the advantages of injection moulding?

Some drawbacks of injection moulding include:

• High upfront costs: Initial costs of injection moulding tend to be high, especially for complex parts or products. Costs correlate with design, testing, and tooling requirements.
• Difficult to adjust: Moulds are made of metal, making them difficult to change. If a manufacturer needs different parts, they have to rework the moulds or even scrap them altogether.
• Not ideal for large parts: Injection mould machines have size limitations. Large items need to be created as multiple parts.

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