About Plastic Injection Molding

The plastics industry is one of the fastest growing major industries in the world. Every year there is an increase in the amount of plastics used in all types of products. A good example of this is the percent of plastics used in today's automobiles compared to 15 years ago.

The plastics injection molding field, at large, is volume oriented. Vendor sources, particularly mold makers and custom molders, are geared to long tool life and high volume production. Plastics equipment manufacturers, likewise, have concentrated almost exclusively on fully automatic, sophisticated injection molding machines whose economics lie in single runs of 100,000 parts or more and in multi-shift operations.

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The continued rate of growth in the industry hinges on the development of improved and new thermoplastics with greater physical properties. This has opened the door to applications never thought possible before. These are emerging both as product innovations and as existing products converted from materials such as metal, glass, wood or paper to plastics for competitive and economic advantage.

Theory of injection molding

The theory of injection molding can be reduced to four simple individual steps: Plasticizing, Injection, Chilling, and Ejection. Each of those steps is distinct from the others and correct control of each is essential to the success of the total process.

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Plasticizing - describes the conversion of the polymer material from its normal hard granular form at room temperatures, to the liquid consistency necessary for injection at its correct melt temperature.

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Injection - is the stage during which this melt is introduced into a mold to completely fill a cavity or cavities.

Chilling - is the action of removing heat from the melt to convert it from a liquid consistency back to its original rigid state. As the material cools, it also shrinks.

Ejection - is the removal of the cooled, molded part from the mold cavity and from any cores or inserts. Repetition of these basic steps in sequence is the process of injection molding.

Prototyping electronic components

Is it possible to develop prototypes faster and cheaper?

The electronic devices and parts manufacturers develop new products in conjunction with the rapid advancement in technology. To stay competitive, it is required to design, test, and manufacture electronic products rapidly.  In addition, "in-house" control & confidentiality are particularly important during the product development phase.

Is it possible to keep the confidentiality in-control, while lowering the production costs? 

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Keeping the designs confidential - at low-cost 

St's plastic injection molding machines offer a significant role in developing devices for the electronic industry at an affordable level. Why? The equipment allow the use of far less expensive molds than would be required for production type molding machines.

By eliminating many of the high cost tooling features of the plastic mold, overall project costs can be reduced into a sensible product development budget, while keeping the confidentiality of designs fully in-house.

St's plastic injection molding solution often cost less than conventional molds alone.  It is truly a low-risk, low-cost alternative to getting the prototypes and samples developed by a 3rd party.  

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Faster "ROI"

Proven in wide range of applications in the electronic industry, St's plastic injection molding machines have a track record of reliable, profitable operation for hundreds of large and small companies representing various industries for over 30 years. Many St-Press users state that their unit paid for itself within the first year. 

MSINCERE TECH assists customers in identifying areas of cost saving opportunities for various applications.

ST is a unique plastic injection molding machine designed for prototype and specialty short-run production, has proved to be an economical means of making plastic parts in small quantities for electro-mechanical devices - especially useful in combining electronic "brains" to their mechanical outputs.

Using low-cost tooling which can be made "in-house" from aluminum and other easy-to-machine materials, the St-Press can produce low volume parts, and even one-of-a-kind prototypes, which are uneconomical to buy or make on the outside.

Some current applications include cable ends, housings, mechanical levers, gears, prototype knobs, switches, spacers and specialty fasteners among others.  A St-Press and tooling can often cost less than conventional molds alone.

Especially useful for new product design and development, the St-Press provides better internal control for proprietary designs, and can shorten lead times.  It also allows quick changes from one thermoplastic material to another to determine which is the best for that particular application.

The wide variety of St-Press applications includes precise, quality plastic molding parts for electronics, medical, automotive and industrial use in model shops, R&D labs, for plastics quality control and material test bars and hundred of other jobs.

Three models of the St-Press with single-shot capacities up to 4 oz. (6 cu. in.) are available with up to 20 tons of clamp force.

Injection moldable thermoplastic materials

The physical properties of injection moldable materials vary from the soft flexibility of gum rubber to the brittleness of glass; temperature resistance varies from complete softening and dissolving in hot water to an ability to withstand a brief exposure to flame.  Costs vary from a few cents to several dollars a pound.
The decision as to which material to use for an application need not be a difficult one since over ninety percent of thermoplastic parts used are made from no more than a dozen basic materials.  Often a part can be successfully made from any one of a number of available materials.  Listed in this section are the most commonly used thermoplastics with a brief description of their most notable characteristics and uses.

• ABS 
  ABS - A.B.S. is a copolymer - mixture of acrylic, butadiene, and styrene.
• Acetal 
  Acetal - Parts which must maintain a springiness such as latches and snap catches are usually made of acetal since it strives to retain its molded shape.
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• Acrylic 
  Acrylic - This material has good optical clarity.
• Nylon 
  Nylon - As any ardent fisherman will know, nylon is a tough material with a high resistance to abrasion.
• Phenylene Oxide
  Phenylene Oxide - This is a high-temperature resistant material used for electrical components such as switch holdings and junction boxes.

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• Polycarbonate
  Polycarbonate - This material is extremely tough. Impact resistance is its real asset.
• Polyester 
  Polyester - Polyester is dimensionally stable and has low moisture absorption.
• Polyethylene 
  Polyethylene - Many food containers used in the home are polyethylene.
• Polypropylene 
  Polypropylene - This is the lowest density common plastic.
• Polysulfone 
  Polysulfone - Polysulfone is strong, rigid and has a very high heat-deflection temperature along with excellent electrical properties.
• Styrene 
  Styrene - It has low resistance to chemicals and heat, will solvent bond easily.
• Urethane 
  Urethane - The wear resistance of this material is often many times that of rubber compounds.
• Vinyl 
  Vinyl - Most electrical wire coverings and plugs are made of vinyl.