Precision molding is the latest technology in plastic injection molding. This type of plastic molding is the most sophisticated process of mold design on the market. It may be used for components that require an exceptionally precise form of plastic injection molding.[1]
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Precision injection molding is a highly technical process requiring precision machines and molds. The process of precision molding is different from conventional injection molding techniques and is often used for developing precise plastic parts with complex geometries. These parts are often used as lightweight replacements for high-precision metal parts in industrial applications.
The precision of a part is dependent on the precision injection mold and its suitability for the engineering requirements. Many factors impact the precision injection mold, including:
Injection molding is a cost-effective way to replicate aspheric, spherical, and freeform surfaces and combine them with mounting features. There are three components to successful injection molding:
The mold used to manufacture polymer optics includes the cavity details, optical inserts, and housing to hold the cavities and inserts. Optical and mechanical features may be combined into one platform with polymer optics, which may lead to a mold with high complexity.
Molds are built to the negative of the final part, and the mechanical features of the part are drafted for easy removal once the molding process is complete. Most optical inserts are created from nonferrous alloys that are diamond turned for high accuracy.
Thermoplastics shrink as they cool. The shrinkage is roughly 0.5 to 0.6%, which must be considered when creating the mold.
The optical injection molding machine, called a press, includes a fixed and a moving platen, a clamping unit, and an injection unit. The mold is placed on the press with one half mounted to the fixed platen, and the other half is mounted to the moving platen. Plastic pellets are melted, fed into the injection unit, and injected into the mold.
A clamp mechanism holds the two mold halves together during the injection process. As the polymer cools, it takes the shape of the cavity details and solidifies to create the final optic. Once cooled, the mold is opened and ejects the finished optic.
Injection molding uses complex variables and controls. Without a robust process, even the best mold will experience drift from tool wear, changes in ambient conditions, fluctuations in resin content, and more. This is why it&#;s essential to find an optics manufacturer with a high degree of skill in scientific molding techniques.
With the proper process, optical injection molding techniques can produce optical components with a high degree of repeatability and accuracy.
Any application that calls for an optical component, such as components for machine vision, scanning, imaging, medical, or general illumination, may use a polymer optic.
You&#;ll often find polymer optics in supermarket barcode scanners, LIDAR, automobile sensors, and medical applications. They are also used in sophisticated laboratory equipment like spectrometers, cleanroom particle counters, document scanners, and more.
As applications grow, polymer optics finds its place in telecommunication products and microstructured surfaces such as diffractive optical elements and microlens arrays. Other examples include imaging systems for near-to-eye displays, PC peripherals, and consumer devices like DVD players and smartphones.
Many of these applications are the result of the advantages that polymer optics have over glass components. These advantages are a direct result of the materials and the injection molding process.
Several factors impact the quality of the finished optical component and the repeatability of the process. The design engineering process must include precise guidelines to reduce defects and ensure top quality. Apollo Optical Systems&#; molding technology creates consistent, high-quality parts that meet or exceed industry standards for successful finished optical components. Contact us to discuss your custom optics project!
Sources:
[1][1] https://www.sciencedirect.com/science/article/abs/pii/S
Dr. Dale Buralli has served as the Chief Scientist for Apollo Optical Systems since . In this role, Dr. Buralli is responsible for the design and optical modeling of various optical systems. These systems include virtual or augmented reality, ophthalmic and other imaging or illumination systems. Additionally, he provides support for optical tooling of lens molds and prototypes, including the development of custom software for both production and metrology. Dr. Buralli got his Ph.D. in optics from the University of Rochester in . Now he is an Adjunct Professor of Optics at the University of Rochester&#;s Institute of Optics.
View all posts by Dale BuralliWhat is precision injection molding?
Creates precise plastic components
Materials should have a low shrinkage capacity
Rely on the precision injection mold
Link to Yihua Mould
A slow and steady process
Uses polymer optics
Many molding processes are known to mass produce products that are used in daily life. However, various industries have parts and pieces that are too complex to be made with ordinary plastic injection moldings. A process called precision injection molding is used for such processes.
But, what is precision injection molding? It is a highly technical process that makes use of precise molds. It is not used to develop whole products, instead, it develops more complex plastic parts.
It differs from convection modeling in many ways, from the materials used to the mold created to the machine used in creating the product. This article tackles all you need to know about this technical process. By the end, you can assess if this is the molding process that you need for your next project.
Compared to plastic injection molding, this method produces precise plastic parts. It does not mass produce whole parts. These products that are made in the process replace high-precision metal parts from different industrial appliances.
The plastic components produced in precision injection molding require a tight tolerance. That means that the requirements for the product have precise and accurate procedures. When not followed, it can break inside the mold.
Products that are produced in precise injection molding are also comprised of complex geometric parts. These items have specific shapes that are needed for certain items in automotive, pharmaceutical, information technology, and medical fields.
Precise injection molding can cause plastics to shrink during the manufacturing process. That&#;s why its materials are different from other injection molding materials.
When materials have a high shrinkage capacity, they melt as they undergo the precise injection molding process. It ruins the product in the end.
The materials used for this molding process need to have a low shrinkage capacity. The shrinkage required is around +/-0.01&#; or +/-0.02&#;. However, many materials can&#;t reach this range.
An example of this would be ABS, a thermoplastic polymer. This kind of plastic can retain its elasticity while going through high temperatures. However, its shrinkage of +/-0.06 is still not appropriate for precision molding. Glass and other resin can be added to reach the desired shrinkage. These help the material absorb the excess heat while keeping the plastic stable.
The precision made during this molding process is achieved through its mold. It needs to suit the design engineering requirements.
To craft the mold, it needs to undergo accurate study, design, and testing. Many elements need to be taken into account for the mold. Here are some of the elements that need attention:
The mold cavity size &#; its position and the number of cavities it has
The precision of the parting surface
The materials used for the mold (this can be made from steel alloys or cast irons)
The bottom plate&#;s thickness
The runner size
Precision injection models are made with tolerances between +/-0.02&#; and +/-0.01&#; or less. All elements mentioned are considered when considering the dimensions tolerance.
A high-precision model is required when creating plastic parts that have tight tolerances. Each part made in a precise injection model needs to be identical. This process can only be applied to plastic parts that are placed and connected with other parts in a fixed form.
Because of the precise products, the manufacturer should not rely on rapid tools for this method. Precise injection modeling is a slow and steady process that makes a high-precision tool.
Polymer optics are used in precise injection molding. This is when CNC machining is used to mold the plastics into precise and calculated shapes. The machines have high pressure that helps improve the quality and precision of the plastic parts. They also manage to repeatedly create an accurate product.
The entire process is automated and conducted through computers through an automatic handling system. It allows the producer to customize the process for the product needed to be molded.
This reduces the cost of labor while increasing production efficiency thanks to its automated process.
Now that you&#;ve answered what precision injection molding is, you can check if you can apply it to some of your products. As stated above, it can also develop a wide variety of complex products.
If you&#;re interested in this process or other molding processes, message Richfields today. We offer various tooling solutions including precision injection molding. Don&#;t hesitate to reach out to learn more about how our services can help your next project.
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