A full-process solution from injection molding design to mass production

Introduction

Injection molding is efficient for complex, precise plastic products. This ultra-simplified document outlines its core process for quick reference.

I. Product Design

Confirm customer requirements (function, appearance, dimensions, regulations) and obtain 3D/2D models. Optimize design for manufacturability: control wall thickness difference ≤20%, set draft angle ≥0.5°-1°, design ribs (0.6-0.8×wall thickness), and confirm reasonable parting lines. Select materials by performance (PEEK for high temperature, TPE for flexibility) with cost and supply stability in mind.

II. Mold Design & Manufacturing

Design mold components: ensure smooth parting and demolding, select mold base per size/injection machine, use mold steels (P20/H13/S136/NAK80, HRC 48-52) for core/cavity with exhaust systems, balance gating (hot runner for material saving, cold runner for cost sensitivity), control cooling temperature difference ≤±5℃, and add ejection/side core-pulling (sliders/angle pins) and auxiliary systems. Use Moldflow to optimize gating/cooling and analyze mold stress. Process mold via procurement → precision machining (rough → heat treatment → CNC/EDM) → inspection (CMM, tolerance ±0.01-±0.05mm) → assembly (smooth part movement).

III. Test Molding & Optimization

Install mold on injection machine, connect auxiliary systems, and set initial parameters (barrel temp, injection pressure/speed, holding/cooling time). Inject low-cost resin for first test, check for defects (short shots, flash, shrinkage). Analyze defect causes (mold/process/assembly), modify mold (polish, adjust gate/water circuit) and optimize parameters, then conduct PPAP with 30-100 samples to confirm stable process.

IV. Mass Production

Optimize production line layout, debug equipment, solidify parameters, inspect raw materials, train employees, and conduct 100-500 piece trial. Run formal production per standards, use robots/automated testing to cut cycle by 10%-20%. Implement quality control: first article inspection, hourly sampling, final inspection (100%/sampling + reliability tests), and unique traceability codes. Maintain mold regularly (clean, lubricate, check vulnerable parts) to extend life by 20%-30%.

V. Conclusion

Strict control of each injection molding link ensures stable quality, efficiency, and cost-effectiveness to meet market demand.