Large Part Injection Molding
We operate injection molding presses up to 1,000 ton to support large part applications, which can process plastic parts maximum to 2000*1500mm. Following is a lit of what you can expect from utilizing injection molding for production of your parts.
- In-house mold production to improve efficient and save cost
- Can process a wide range of plastic materials
- Robotics and in-house manufacturerd end-of-arm tooling ensure effcient cycle times
- Additional capabilities inclding bonding, painting, printing, assembly and custom packaging
Detailed Description Large Part Injection Molding Process Technology
Large injection molding machine features and capabilities:
- Machine tonnage: The tonnage of large injection molding machines is usually between 500 tons and 4000 tons, which can cope with various sizes and weights of products.
- Maximum molding size: Depending on the machine and mold design, it is usually possible to produce parts with a diameter of more than 2 meters, and the thickness can reach a few millimeters to tens of centimeters.
- Multi-cavity mold technology: Through the use of multi-cavity mold design, it is possible to produce multiple parts of the same or different shapes at the same time in a single injection process, improving production efficiency.
Detailed explanation of process steps:
- Design stage: First of all, according to customer needs, product design and mold design to ensure that the function, shape and structure of the parts can meet the requirements.
- Mold manufacturing and debugging: High-precision molds need to go through accurate processing and debugging to ensure the accuracy of the molding process.
- Injection molding: the plastic particles are heated to a molten state, and the molten plastic is injected into the mold by an injection molding machine.
- Post-treatment: Parts after forming may require post-treatment processes such as cutting, trimming, drilling, and surface treatment.
Selection of available materials:
- Engineering plastics: For example, polycarbonate (PC), Nylon (Nylon), etc., are often used in applications requiring high strength and durability.
Thermoplastic elastomers: such as TPE, can be used to produce parts that require flexibility.
Fiberglass reinforced plastics: Enhance the strength, rigidity and heat resistance of plastics for parts that withstand higher mechanical loads.
| Name | Detail |
|---|---|
| Maximun Size |
78.74in. x 59.05in. x 39.37in. 2000mm x 1500mm x 1000mm |
| Mold Cavities | Single or multi-cavity |
| Mold Life | Unlimited (We will open a new mold if the old one worn out) |
| Mold Storage | Forever (Only damage the mold after your permission) |
| Mold Material | Tool steel, stainless steel, aluminum |
| General Tolerance | Normally +/- 0.008in.（0.2mm) |
| Mold Lead Time | Generally 30~40 days for large part injection molding |
| Finish | Description |
|---|---|
| SPI A1 | 6000 grit diamond, surper high glossy finish |
| SPI A2 | 3000 grit diamond, high glossy finish |
| SPI A3 | 1200 grit diamond, normal glossy finish |
| SPI B1 | 600 grit paper, fine semi-glossy finish |
| SPI B2 | 400 grit paper, normal semi-glossy finish |
| SPI B3 | 320 grit paper, normal semi- |
| SPI C1 | 600 grit stone, fine matte finish |
| SPI C2 | 400 grit stone, medium matte finish |
| SPI C3 | 320 grit stone, normal matte finish |
| SPI D1 | Dry blast glass bead, satin textured finish |
| SPI D2 | Dry blast, dull textured finish |
| SPI D3 | Dry blast, rough textured finish |
Large Part Injection Molding Advantage
High precision manufacturing:
Large injection molding technology can ensure the high precision of products, especially suitable for plastic parts with complex shapes. In automotive, home appliances, electronics and other industries, the accuracy of size and shape directly affects product performance and appearance.
The economics of mass production:
Due to the high degree of automation of the injection molding process, once the mold design is completed, stability and efficiency can be maintained in the mass production process. For mass production, injection molding has obvious advantages in cost control.
Material diversity:
Provide a variety of plastic material options, such as ABS, PC, PP, PE, Nylon, etc., can meet the needs of different strength, heat resistance, chemical corrosion resistance. For example, PP plastics can be used to make parts with light weight and strong chemical resistance, while PC materials can be used to make high-strength, transparent parts.
Manufacturing capability of complex parts:
Large-scale injection molding enables the manufacture of complex geometries, such as plastic parts with tiny pores, curved surfaces, and multiple inserts. It is especially suitable for parts that require structural optimization and versatility.
Application Areas
Automotive industry:
Large injection molding is often used to produce body parts, interior trim (such as bumpers, dashboards), and exterior cladding. It can realize complex embedded functions, such as integrated sensor interfaces, electronic modules, etc.
Home appliance Industry:
Large home appliance housings, such as those for refrigerators and washing machines, are usually produced by injection molding processes that ensure a high standard of appearance quality and functionality.
Medical equipment:
Injection molding technology is widely used in various equipment enclosures (such as syringes, brackets), control panels, and single-use medical devices in the medical industry. Because these products need to have high precision and durability.
Industrial Equipment and Electronics:
For the manufacture of large mechanical housings, electronic equipment housings, connectors, inserts, etc., especially suitable for products requiring high strength and durability.
Consumer Goods:
Used in the manufacture of large furniture parts, sports equipment shells, toys, electronic accessories, etc., can meet the personalized customization needs in appearance and function.
Optimizing Large Part Injection Molding
Mold & Tooling Service
Design for Manufacturability
Surface Finishing
Assembly Manufacturing
FAQs of Large Size Injection Molding
What is considered "large size" injection molding?
Large size injection molding typically refers to parts with surface areas of 100 square inches or more. It generally requires injection molding machines with clamping forces of 500 tons or higher.
What are some key considerations for large size mold design?
Important factors include:
- Proper gating and runner system design
- Optimized cooling channels
- Structural reinforcement to prevent warpage
- Ejection system capable of handling large, heavy parts
- Venting to allow air to escape from large cavities
How to control the cost of large parts injection molding production?
Answer: The cost of large injection molding production is mainly determined by the following factors:
- Mold costs: Large injection molded parts often require larger, more complex molds, which can lead to higher mold development and production costs. The design and material selection of the mold will directly affect the cost, and complex mold design requires more processing time and technology.
- Material cost: Due to the large size of large injection molding products, the raw materials used are correspondingly increased. Selecting the right materials and optimizing the amount of materials used are the key to reducing material costs.
- Production efficiency: The operation time of the injection molding machine in the production process, the length of the injection cycle and the labor cost in the production process will affect the overall production cost. By optimizing the injection cycle, improving the utilization rate of equipment, and reducing the defective rate, the production cost can be effectively reduced.
- Post-treatment and assembly costs: Large injection molded products often require post-treatment (such as cutting, deburring, etc.) and assembly. Proper planning of these steps to reduce unnecessary post-treatment and overhaul work can significantly reduce costs.Production costs can be effectively reduced through reasonable selection of raw materials, optimization of mold design, improvement of production efficiency, reduction of waste, and reasonable arrangement of post-processing processes.
What are the typical materials used in large-part injection molding?
Large-part injection molding often requires materials that can maintain their properties and structural integrity over larger surface areas and volumes. The typical plastic materials include:
- Polypropylene (PP)
- Polystyrene (PS)
- High-Density Polyethylene (HDPE)
- ABS (Acrylonitrile Butadiene Styrene)
- Nylon (Polyamide – PA)
- Acetal (Polyoxymethylene – POM)
- Polycarbonate (PC)
- Acrylic
