Is Scientific Injection molding rocket science?? Definitely not. Scientific injection molding is nothing but processing or injection molding a part by understanding the property of the raw material. That’s all. And not by adjusting it according to the condition of the molds.
You must have seen a lot of ppts talking about attending to any particular issue, suppose flow or blush coming near the gate, solutions like increase the temperature, reduce the injection speed, increase the speed, reduce the temperature, many contradictory solutions for one issue, etc. Understanding the root cause is most important. Injection molding is not just a trial and error method. Every problem has a specific cause to it. It's not like we are trying something and it does not function and then somehow reach the solution. This is not how it works.
Firstly, understanding the raw material and processing the part. Secondly, understanding the feed system in detail. I repeat, the feed system should be understood in detail. Feed system is not just an experience. It is a science based on every raw material we are processing. If we are not able to crack it, it is impossible to do scientific injection molding even if we have all the spreadsheets with us.
I happen to see a lot of people around who have all the spreadsheets of top companies who do scientific injection molding. Nobody is able to implement it. Why is it so? Because the knowledge of raw material is missing, knowledge of the feed system is missing. That’s it.
And scientific injection molding can only be implemented if we know about the raw material property, the non-nutonomous behavior of the raw material, the sheer rate of the raw material, the viscosity of the raw material, laminar flow property and the feed system in depth, which means sizing of the feed system and which gate has to be given for which runner, what should be the size of the gate, exactly by calculation, what should be the land length of the gate, what should be the sheer rate in the gate, even the shape of the gate itself matters. It is not just a flow path through which the raw material flows. It is very important in implementing scientific injection molding.
And of course, to implement scientific injection molding, I will tell you just the experience of injection molding machine process setting only will not help.
To implement that, comprehensive knowledge about the raw material, part design, mold design, troubleshooting, understanding the real root cause, not by Hit and Throw method and a solution to that, the rheology property of the raw material, CAE analysis or mold flow analysis and its real interpretation. Running a mold flow is easy but interpreting it is very important, and understanding the feed system in-depth.
Scientific injection molding is the simplest molding process and its advantage is that we get a consistent part. Even though there is a variation in the input raw material ie, the natural variation which is bound to come in the material, any change in the weather or atmosphere, scientific Injection molding has the capability to deliver the part consistently even though there is a natural variation which is bound to come in a molding process.
You may connect with us, if you wish to establish Scientific injection molding procedure in your shop floor.
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