There are few operations that are as cost-effective and as efficient as plastic injection molding in producing large volumes of precise parts and components. This process, however, is not without is potential problems.
Often new companies in the plastic injection field have more problems with molds and the process due to lack of experience and knowledge of the process and in working with the equipment. Some of the most common errors are easy to make and can even occur with experienced staff if there is an oversight or miscommunication during the project.
Working From Different Design Specs
It is not uncommon for there to be multiple design discussions, revisions, and modification. This can often leave a lot of design versions on computers or be sent back and forth online.
A simple option is to always number or label designs and modifications so that it is easy to immediately verify the plastic injection molding design is the correct version when setting up the mold and creating the prototype.
Wall Thickness Issues
As a material, in liquid form, is injected into the mold it rapidly spreads throughout the mold with precision and accuracy. However, once in the mold if there are extreme differences in the wall thicknesses the liquid will solidify at different rates.
In areas where the walls are thin, the plastic will cool immediately. If thick walls are next to thin walls and without a graduated change, the thick plastic will not cool as quickly, allowing it to run back over the thin wall areas. This will create deviations and variation in the final part once released from the mold.
This same issue can also cause problems with speed and efficiency. The molds will have to cool longer in the mold, slowing down production that can add up over a large volume production run.