Insert molding is a highly efficient process by which metal stampings, bushings, electro-mechanical parts, filtration materials, and other discrete parts are combined into one component through injection molding of thermoplastic around the carefully placed inserts/parts.
Multi-component molding is the composition of two or more different components into one plastic part to achieve a specific function by means of the injection process. The specific functions can be either hard or soft combination of PP and TPE, core/skin combination, and multi-color design etc. The mold can rotate, shuttle or swivel to bring the cavity into the filling position for each component.
Thermoset injection molding process begins by adding granular or pelletized material to a hopper. Material is gravity fed into a barrel and screw, which heats and moves the material toward the mold. Material is then injected into a heated mold through a runner system to reach all the cavities under high pressure. When the mold cavities are adequately filled, the parts cure to a solid form. The mold then opens for part removal, and some parts simply drop into a box, while others are removed by hand or automatic take-out equipment.
Injection molding of liquid silicone rubber (LSR) is a process to produce pliable and durable parts in high production volume. LSR is a high purity cured silicone with low compression, great stability and ability to resist extreme high and low temperatures. Due to its thermosetting nature, LSR molding requires special treatment before it is purged into the heated cavity and vulcanized. Typical applications for LSR are products that require high precision such as: seals, sealing membranes, electric connectors, multi-pin connectors, infant products where smooth surfaces are desired such as feeding bottle nipples, and medical applications as well as kitchen appliances such as baking pans, and spatulas, etc.
Powder injection molding (PIM) is a manufacturing solution for producing intricate parts in medium to high volumes (10,000 to over 2,000,000 parts annually) using fine (<20 μm) metal or ceramic powders. PIM is well suited for parts weighing from 0.1 to 250 gm. Cross sections are typically less than 6.35 mm and tolerances can be within the order of ±0.3 to 0.5%. PIM is capable of transforming complex design concepts into high precision products using a wide range of raw materials such as carbon steels, low alloy steels, stainless steels, low expansion alloys, tool steels, soft magnetic alloys, super alloys, conductive materials (e.g. copper), and ceramics.
In-mold Decoration (IMD) offers long lasting decoration with a wide variety of colors and surface textures. Unlike the traditional surface printings (such as: spray coating, silk screen printing, and electroplating etc.), the IMD process places the printed film on one side of the mold and the melt plastic resin is then inject onto the back of the film and therefore bonded with the plastic resin as an integral unit. The IMD molding is able to bring all kinds of visual effect of material such as: metal, leather, wood or stone pattern etc. onto the surface of parts. The IMD molding technology can be mainly classified into IMR, IML, and IMF. IMR for In-mold Rolling, IML stands for In-mold Labeling (2D), and IMF for In-mold Forming (3D).