China not simple workshop in plastics industry

China vs Us in plastics industry

China is not simple workshop of plastics industry in the world

If you come to Shanghai, and stay for a long time, your feeling is, America has to face the challenge from China, China is not the simple production workshop in the world. Companies such as Apple, China has become a part of the manufacturing chain, people around the world to order Apple products that produced in China. Chinese picture in the plastics industry is more beautiful. The moment of a news, Chinese stock Corporation, home appliance maker Haier Group acquired general electrical appliances, home appliances with Manufacturing plants and 12000 employees. Haier group’s strategy and strategic thinking direction in short, it is like any large multinational manufacturing company. At the same time, due to the problem of the exchange rate, a large number of Chinese companies are all over the world acquisition, which and the plastic injection molding industry related news, plastic chemical acquisition of German plastics machinery giant Krauss Maffei group. Since 2000, China has been the world’s largest injection molds and plastic products market, not only is the price, China also has some of the best technologies. Therefore, from this point of view, the role of Chinese injection mold, has not made at least the profit of the industry supply chain link.

Western people  view of china plastics industry

Western people generally have a point of view. China is still a challenge, but also often want to write their own rules, and do not comply with the rules of the past, like the United States Wild West, for example, in intellectual property, especially for smaller manufacturing companies. Not long ago, American mold equipment supplier progress components company, submitted a complaint against China local company selling fake products. Presidential Gelunsidake progress components of a company’s estimate, the company 80 percent of the products and the company’s name. In China all is fake. Despite the many aspects of the reform in China, in the aspects of intellectual property rights, China has not made sufficient progress, so they are worried that China’s reform can not continue. But the Chinese plastics industry market is full of temptation, no one is willing to give up this market. Snap this market, which for most global company seems to have enough.

We to the data speak,  Last year, the German plastics industry and rubber machinery industry to the United States and China issued the same number of machinery and equipment ($7 billion to 8 billion dollar value). Germany is the world’s largest plastics industry machinery exporter, for the United States, China is the largest export market. According to reports, China’s domestic plastics industry market is about 8 billion usd annual, compared to the United States market, According to industry experts estimate that the value is only half of it. The size of China’s plastics industry market will naturally create ,some of the very global competitiveness of the company. They have hone their teeth in the domestic, and now they began to take risks. China’s injection mold is still full of vitality in the world in plastics industry market. Last year, China’s demand for plastic has increased by ten percent. Now a popular saying, to bring manufacturing back to the United States, some argue that some of the manufacturing sector is leaving China to other low-cost countries. But no matter how much reflux really happened, China is still a strong force in the plastic injection molding industry. At the same time, Louisville, Kentucky, Ge appliances factory headquarters is mentioned in many media reports data shows an example because it increases the thousands of jobs. Haier Group will own the company. This is still a good example, the return of the United States makes this China’s injection molding plant in the United States to become the largest injection plant It is speculated that these investments Haier group, not only to boost the U.S. economy, but also to revitalize China’s plastics manufacturing industry recovery. This shows that the global manufacturing complex relationships, mutual win reciprocity, which is today news to share with you.

injection molding plastic deformation method

Eliminates when injection molding plastic deformation method

plastic injection molding parts

plastic injection molding parts

The causes of deformation
1) the shape of products, especially forming shrinkage relationship with product thickness caused by residual stress
2) Due to the forming conditions of residual stress in
3) parting the residual stress produced in
4) and deformation due to insufficient cooling time

2. The associated knowledge
1) the deformation of the products (warping, bending, small wrinkles) as well as the reasons of the crack.The residual internal stress in the products.Molding set conditions should be set in eliminate products of internal stress direction. Namely improve material barrel temperature and mould temperature, the material liquid get better state, the injection pressure is not too high.
2) in order to reduce the residual stress, annealing processing, namely under thermal deformation temperature of 10 degrees, more than 2 hours of heating has the effect of stress relief. But this way because of the high cost of annealing and use is not common.
3) if the mould cooling hole not to cooling homogeneity of products, also can produce residual stress, which means that the cooling hole can’t be too shallow.

Third, solution.
1) instant: sufficient cooling solidification in the mould (chronograph longer cooling time), and improve the temperature of the material, reduce the injection molding pressure.
2) short-term: make mold cooling uniformity.
3) long-term: avoid the thickness of products, where product thickness large set gate (1-1), caused by a straight line easy to warp, make it big R curve, products reversible bending die, increase the number of ejection rod, increase the draft.

Four, differences in material:
1) the crystalline materials (poly (PVC), polypropylene, pom, nylon),injection molding shrinkage rate, and easy to cause bias, non-crystalline material (polystyrene (PVC, ABS) easy to cause residual stress.

Five, the reference items:
1) use orthotics keep at room temperature after molding, to prevent deformation, slightly but not hope too much.
2) in the box forming of thin shape, bending caused by injection molding temperature, this is common thermal expansion

Types of plastic injection molds in China

Types of chinese plastic injection molds

plastic injection molds in china

plastic injection molds in china

Plastic injection molds to create objects, injection molding plastic is forced into the mold cavity. They are often used to scale manufacturing operations, creating new products, such as toys, kitchen utensils, caps, mobile phone sets. You can use the injection mold “flash line” extra plastic around the seams discovery projects. There are four main types of commonly used plastic injection molds.

Cold runner mold

Cold runner mold, such kind of injection mold is the most common type. The gates and runner mold used for injection molding plastic in each mold cavity. However, the sprue and runner and some hardened once solidified. Workers then these works and recycling. This may cause the waste problem, which may make their economic use.

Two plate plastic injection molds

Two plate cold runner mold is so named because they are characterized by two plates together. Only a parting surface that must be located in the runner. This is the easiest cold runner mold.

Three plate plastic injection molds

Three plate cold runner mold has three, which means that there is one pair of parting planes. Three of the manifold, the movable plate and floating panels. Contains half of the gate hot runner plate and the runner-up. The injection system comprising half of the movable plate and the geometric shape of the part. The other half of the rotor included in the floating plate and geometry. The system can be located in any of the parting, and anywhere on the surface can be selected through the sheet to provide flexibility.

Hot runner mold

Hot runner mold provides a different way of plastic. As part of the runners, although a plastic syringe and cool the cold runner, the hot runner mold in the mold and stored in the temperature higher than the melting point of the plastic. This means that the gate and runner sclerosis will never have a chance. This also reduces the amount of plastic waste. However, the hot runner injection mold requires more skill and maintenance, and have a higher baseline costs. However, they tend to save materials according to their own.

Chinese Injection mold working process

Chinese Injection mold production process
Injection mold manufacturing process and production process of other industrial products, are starting from raw materials through various processing into the whole process of the finished product. Many types of mold, its structure, purpose and requirements also vary, but their production processes also have in common, can basically be divided into five main stages: the production of technical preparation stage, the preparation stage of raw materials, parts and components processing stage, assembly and commissioning phase trial identification stage.

1. Production of technical preparation phase:

This phase is the basis for the production of molds, injection molds for quality, cost, schedule, and management has a significant impact. Production technology stage work includes: Die overall design, preparation of component design, process technology files, develop, mold and other materials cost estimate of the fixed and fixed working hours.

2. The raw material preparation phase:

This phase should be one of the most important work for the preparation of the mold production. The raw material preparation is one of the most important work, is to prepare a variety of material reserves, because the type of injection mold, structural variety, raw materials required are very different, the blank is necessary according to the desired shape of the mold parts, process dimensions, materials, etc. to prepare , to be in the form of rough castings, forgings and under various forms material.
In addition, to complete a mold production, but also requires a lot of purchased parts and spare parts, such as fasteners, standard parts used in the assembly mold etc; factory can not produce or temporarily produce parts, such as templates, mold base and so on. In short, it is necessary, among other raw materials production molds can be processed in the factory all ready

3. Parts Processing Stage:

This stage is an important stage to ensure the accuracy of the mold, which mainly include: machining, special of surface processing and heat treatment. Machining is the use of cutting tools for metal materials processing. Is known, the mold is assembled from metal parts almost up. To get the parts comply with requirements of the drawings, the use of mechanical processing is its main tool. Therefore, the machining process is the largest.

Followed by special processing, the structure of the mold rather special. Because plastic is a three-dimensional piece, it is shaped by a combination of male and female mold cavity derived. This cavity with a surface that is difficult to deal with the general machining, even if reluctantly working out, their quality is difficult to guarantee. Therefore, you need to use special processing, such as EDM. Electroforming processing. These special processing methods become indispensable processing methods.

The third is the surface finish, the general requirements for plastic surfaces are high, requiring plastic surface gloss, rounded appearance, which requires corresponding cavity surface is very smooth and shinning, are generally due to the cavity surface, with usually difficult to guarantee the quality of machining, which requires specialized mold surface finish, mainly polishing, chemical polishing, ultrasonic polishing, pressing polishing, blasting polishing.

Fourth, heat treatment, injection mold production, all important parts to be heat-treated, and some parts have to deal with many times. Since heat is the primary means to change the properties of the metal material. As the mold is generally a single piece production, production costs a lot of money, people always want to make more use of it some time, so that the mold can require durable, and heat can be in part without changing the shape and size of the change in its internal organization and performance is important to ensure that the intrinsic quality of the parts method.

4. Assembly commissioning phase:

This phase is to assemble the various parts together and debugged. The quality of assembly work, the quality of the mold walked decisive role. Assembly is a highly technical work, even a small mistake can make a little mold not produce qualified products to.” Assembly” is generally divided into the component assembly, parts assembly and final assembly, commissioning assembled, which is to adjust the relative positions of the parts, with the gap and structural tightness and so on. This is the key step is easy to use.

5. Try to identify stage:

This stage is a good debugging mold ,mounted on the injection molding machine for trial, according to the design requirements for the operation, see the mold clamping, mold is flexible and meets the requirements, the quality of the resulting plastic article is qualified, thereby to identify whether the molds qualified. If accreditation, considered as a injection mold to complete this entire process of production

Injection molded products inspection methods

Injection molded products quality inspection methods
In China,Whether produced after injection products meet quality standards, must be tested, a common quality test methods are the following two way.

injection molded plastic in china

injection molded plastic in china

(1) full inspection

It was called full inspection is individually tested for injection products, we have talked about “full” refers to the number of all the plastic parts produced, rather than the entire value of the quality characteristics tested. In determining the test items,Test costs are generally low, the implementation of all product inspection is to have a higher quality requirements.

Such as plastic parts Dimensions test is easier and can be fully tested, and the requirements of the position and some plastic parts crucial, a great impact on the quality, but also the need for full inspection. Not plastic parts for each test must be carried out in full, as it cost too much time-consuming and laborious. Usually occurs when the following conditions using full inspection.

1) found that more unqualified plastic parts, plastic parts or the whole batch are unqualified, the need for follow-up products for full inspection.

High single value

2) injection products, even when a scrap will bring great losses.

3) If the product quality problems, give people life safety or safety hazard when great.

(2) Injection molded plastic sampling inspection

The so-called sampling inspection,, is from a group of randomly selected plastic part of the test conducted. By this test section of plastic parts extracted to make the evaluation of quality of these plastic parts. Compared with the full inspection sampling inspection, it tested a small number of plastic parts, low-cost test, test speed. Sampling inspection and batch size of the number of samples, volume, sample quantity; small quantities, less sampling; as long as the appropriate number of samples, the test results have a high accuracy. Usually by random checks in the following cases.

1) Some of the Injection molded plastic parts that  mechanical and physical properties need to destructive testing, this will bring damage to the plastic parts.

2) more than the mass production of plastic parts, plastic parts produced quantity particularly large, want to save test time and test costs.

3) the production of raw materials in Injection molded plastic parts, there are a lot of raw material is powdered, granular or liquid form, the raw material for these multi-use sampling. Compared with the full inspection sampling inspection, although there are a small number of test and low test cost advantages, but also the following problems: First, when the second installment of the plastic parts, even after sample testing has been considered qualified, can not believe that this batch of plastic parts plant each plastic parts are qualified, which may also exist a very small amount of non-conforming product. Second, the sample tests will inevitably appear judgmental errors, this is the vast majority of qualified products, due to sampling bias, but judged unqualified; or could have been substandard goods, has become qualified. Therefore, in order to determine the probability of error is controlled within a reasonable range, often need to coordinate the use of mathematical statistics methods.

In short, the full inspection and sampling test has its own characteristics, and applications and problems also vary, depending on the circumstances test methods should be chosen to adapt. Mostly due to the injection mold products for mass production, it is more to take sample tests

Advantages of plastic medical instrument

Advantages of plastic medical instrument

plastic medical instrument

Use plastic medical apparatus and instruments called a major initiative of the medical profession. From drug and pharmaceutical packaging products, to syringes, tubes, surgical instruments and other disposable medical equipment can be seen in the presence of plastic instruments.
Disposable medical instrument market demand potential is so great ,why largely because of its advantage following aspects:
1, light weight, and effort, help reduce fatigue caused by surgery doctor for a long time. More suitable for human blood and muscle tissue, so the more effective.
2, tough is good, anti-permeable, durable, plastic parts can also be used normally at high temperatures.
3, Transparent , medical procedures can be better observed, especially during surgery.
4, easy to molding, suitable for the production of a variety of shapes, complex medical equipment and supplies, and simply use the low-cost production process. Use disinfectant or sterilizing temperature corrosion does not occur, or color change phenomenon.
5, compared to metals and other raw materials, low cost, suitable for the production of disposable consumables, and after sterilization of packaging materials used to help reduce the risk of infection.
6, As compared with ceramic or the like brittle glass material, a more secure, especially as packaging material.

Aging population will up medical instrument quantity demanded

With the increase of the proportion of population growth and an aging population, the demand for plastic medical instrument continued to expand, particularly into the body of the equipment. The use of medical instrument to diversify from a single, volume size is shrinking, now one can replace equipment more than the previous equipment. Because many outstanding advantages of plastic medical equipment, pharmaceutical industry in the future course of development, its market share and influence will grow.

Powder Injection Molding Market

At present, the ceramic injection molding technology to provide a better, cautious, beautiful product, for the replacement of metal injection molding. In 2015, medicine and the oral cavity orthodontic industry achieved nearly 25% of the global market share, the main reason is that the powder precision injection molding technology to improve and create, forming an industry’s main products. These brackets are very small and precise plastic parts.

Precision Injection Mold Manufacturer Industry Development In China

In China,Precision injection mold industry development is getting better and better

injection mold manufacturer in china

Precision injection mold manufacturer

Many industry rising to the requirement of the mould, so precision injection mold manufacturer industry development gradually hot up, with the vigorous development of the electronic information industry and traditional industry informatization modification, plastic mold market prospect of a vast, global high-grade, china precision plastic injection mold manufacturer market is in short supply situation.

In recent thirty years(since 1978), China plastic injection mold manufacturing level has been improved greatly, the production of large single set weight of the plastic mould has reached more than 50 ton, the accuracy of precision plastic injection mold making has reached to 3 cm, already can produce a multi-cavity mold, plastic mold cavity encapsulation molds,7800 high speed, molding has been able to produce more than 4 m / min high-speed plastic, different materials, plastic mold and dual color injection mold cavity.

Affected by the variety of national policy and the continuous expansion of market space, automotive industry, IT industry, home appliance industry, Medical industry,packaging industry momentum very rapidly in recent years, not only has made great development in terms of capacity, but also in the aspect of the industry’s high-end has a great progress, therefore, in the industry including the three aspects has a strong injection mold manufacturing needs. Part of automobiles, IT products of plastic parts need to be all through the molding, eventually to become a finished product for sale.

With the rapid prototype mold development ,the plastic industry and general engineering plastics in such aspects as strength unceasing enhancement, the application range of the plastic products are also constantly expanding, Amount of plastic products is also rising.

Automotive injection mold manufacturing industry

automotive injection mold making

Automotive industry drive china injection mold manufacturing

Auto injection mold is still the most widely manufacturing in china, the field of industry development is rapid, every new car invest need thousands of pair of injection molds, auto makers has formed with the closely matching mould enterprise development, research and debugging technology, production of strategic alliance. Automotive are increasingly high strength plate in order to reduce weight, also for some ultra high strength plate hot forming and the corresponding hot forming ,mold has naturally become the development trend.

Automotive Industrial  to use plastic ratio will increase and the development of new materials, including all kinds of new plastic, modified plastic, metal, plastic, magnesium alloy, composite material, and so on, this requires a new forming technology, which also requires that have adapted to the new mold. According to CNMOULDING company analyze, plastic injection molding in the future in the market, the proportion of total plastic mold in the china will gradually increase, its development speed will be higher than other mold manufacturer.

“Automotive Injection mold to elegant, requires good appearance generous, internal defects, this would require careful, precision injection mold with high quality. At present, the refinement has a big gap, refinement is often ignored by some companies, the results fell short.” Company, I think that the injection mold fast and efficient production, the injection molding enterprises try to shorten the mold production cycle time, to plastic molding the user mould as soon as possible, on the other hand is more important, the user can you provide a injection mold to production products more quickly and efficiently. Such as more than a multi-cavity mould production, laminated mold, forming time and make good use of hot runner technology to shorten the use of multilayer composite technology, mould decoration technology, highlights non-mark injection molding technology, testing technology and process of composite technology and transfer technology and so on, at the same time stamping forming process intelligent also requires intelligent mold to adapt.

Precision Injection mold market in automotive sector

Precision injection mold , we call PIM here. Along with the progress of production technology, the automobile industry also is an important application field of PIM technology. Gearbox, engine, locking mechanism, turbocharger, steering system, and various electronic systems embedded in automotive injection molded parts, are very powerful and highly complex. Automotive industry in the 2015 market, PIM has accounted for more than 21% of the market share, an increase of 10.4%。Including forecast analysis data and digital map data. The use of finely dispersed powders helps to produce a highly uniform micro structure, which helps to significantly improve the micro structure of investment casting products needed in the automotive industry. These factors significantly affect the PIM market growth

Precision injection molding process flow

Process flow of Precision injection molding and the common plastic molding difference

The characteristics of precision injection molding is: the size of the injection molded parts with high precision, small tolerance.

precision injection molding

precision injection molding

To achieve the requirements of precision injection conditions must be met:

(1) the mold material is better, rigid, cavity dimension precision and template between positioning accuracy is higher, lower surface roughness.

(2) to adopt precision plastic molding machine.

(3) to adopt precision molding process.

4) to choose suitable for precision injection molding process of the material. Commonly used precision molding materials have several: POM, POM = CF (carbon fiber), PNM = GF (glass fiber), PA \ FRPA66 (enhanced PA), PC, etc.

Precision injection process can ensure the size precision injection molding is the important way to control the shrinkage of injection molded parts, including: thermal contraction, disguised contraction of molded parts, orientation and compressed contraction and elastic recovery.

Common injection molding features are: precision is not high, the size of injection molded parts are typically can be assembled into standard, requirements for the appearance of the injection molded parts is relatively high, if necessary, may use the second processing (oil, for example) to improve the appearance of defects. Ordinary injection molding don’t need to use special precision injection molding machine, also do not need to specially designated materials, general common thermoplastics can be used to production. So ordinary injection molding technology is widely used in modern plastic industry.

Introduction to 3D printing technology

Last news about 3D Printing -Cybersecurity Risks In 3D Printing

The first 3D printing general electric commercial jet engine, has been certified by the Federal Aviation Administration of the United States.Scientists found that 3D printing in the direction of printing and insertion, there are network security impact.They reported that the orientation of the product during 3D printing could make as much as a 25 percent difference in its strength.And economic concerns also influence how a manufacturer prints a product.Due to the existence of this problem, 3D printed parts, such as metal molds use in injection molding for high temperature and pressure conditions, may eventually lead to failure of product development.This may be a good thing for all injection mold manufacturers, should be for the company’s business will not give too much to steal

3D printing, is a rapid prototyping technique, which is a digital document based on the model, it was used powdered metal or plastic materials and bonded by the printed layer by layer technology way to construct the object.
3D printing materials are usually printers using digital technology to achieve. Often in the mold manufacturing, industrial design and other fields are used to make the model, and then gradually for direct manufacturing of some products, there have been made using this technique to print parts. The technology in the jewelry, footwear, industrial design, architecture, engineering and construction (AEC), automotive, aerospace, dental and medical industries, education, GIS, civil engineering, guns, and other fields have applied.

Everyday life of ordinary printer can print flat items used computer design, and the so-called ordinary printers and 3D printer works basically the same, but somewhat different printing materials, printing materials are ordinary printer ink and paper, while the 3D printer built with metal , ceramic, plastic, sand and other different “printed materials”, are real materials, the printer connected to the computer through computer control can be “printed material” layer laminated together, eventually became the blueprint on your computer kind. In layman’s terms, 3D printer can “print” of a 3D object in real devices, such as printing a robot toy car printing, printing of various models, and even food, etc.. The reason colloquially called “printer” is a reference to the technical principles of ordinary printer, because the process of layering and ink-jet printing process is very similar. The three-dimensional printing technology called 3D printing technology.

There are many different 3D printing techniques. They differ in the way that the material is available, and to create build parts with different layers.

[3] 3D printing materials are commonly used in fiberglass nylon, durable nylon material, gypsum materials, aluminum, titanium, stainless steel, silver, gold, rubber-like material.

type Technologic Raw material
press 熔融沉积式 (FDM) Plastics molding
string 电子束自由成形制造(EBF) Any alloy
coins 直接金属激光烧结(DMLS) Any alloy
电子束熔化成型(EBM) Titanium alloy
选择性激光熔化成型(SLM) Titanium alloy,Cobalt chromium alloy, stainless steel, aluminum
选择性热烧结(SHS) Plastics molding
选择性激光烧结(SLS Plastics molding
powder spray 3D printing 石膏3D打印 (PP) Gypsum
Layer press 分层实体制造(LOM) Paper, plastic film, metal film
Photopolymerization 立体平板印刷(SLA Photocurable resin
数字光处理 (DLP) Photocurable resin

3D printing technology is not used in mass production, so some experts advocate 3D printing is the third industrial revolution, this argument is just agimmick.Foxconn OEM for Apple iPhonehas been for many years.Gou made with 3D printing phones to illustrate 3D printing products can not only see, because we can not add electronic components, electronic productscan not be produced as the amount of these products.3D printing even without the production of electronic products,but by material constraints,other products can be produced very little, “even if the products produced, can not mass production, but also on the brokenYishuai.
“3D printingis indeed more suitable for some small-scale manufacturing,especially high-end customized products, such asauto parts manufacturing, although the main material is plastic, but the future of metallic materia ls will certainly be applied to 3D printing in the past,” said Crump, 3D printing technology has entered thedental, jewelry, medical industry,the scope of future applications will be more widely available.

3d printing gun

3d printing + injection molding in china