We specialize in Scientific Injection Molding for all the products we manufacture for our customers. Our team of design, quality, manufacturing, and process engineers partner with customers to develop and optimize processes using a Scientific Injection Molding approach. We work relentlessly to ensure that deliverables are executed at each stage of the Product Development and Product Transfer processes. Our extensive experience and capabilities enable us to manufacture products and devices with the most demanding, unique requirements.
Scientific Injection Molding is typically used in the production of complex parts and components where small variations in molding variables can severely impact the process or finished product. Therefore, the goal of Scientific Injection Molding is twofold:
- Develop a process that produces repeatable results with minimal variation
- Optimize dimensional or mechanical characteristics of a molded part
When developing a molding process using Scientific Injection Molding, key inputs such as time (fill, pack/hold, etc.), temperature (melt, barrel, etc.), and pressure (hydraulic, injection melt, cavity, etc.) are meticulously examined, adjusted, and controlled to ensure consistency in the manufacturing process. This promises a quality part is produced every time
In Scientific Injection Molding, the fill and pack/hold stages are separated (i.e. the molding process is “Decoupled”). This minimizes variation between shots and improves consistency applying the non-Newtonian fluid behavior of the thermoplastic material. Scientific Injection Molding can be broken down into three distinct phases:
- Fill: During the Fill phase, the cavity of the molding tool is filled between 95-99% of the total available volume. This partial filling of the tool guarantees the foundation for consistency between shots.
- Pack/Hold: During the Pack/Hold phase, the remaining volume is filled and the plastic is compressed to fully “pack” the cavity.
- Cooling/Recovery: During the Cooling/Recovery final phase, the part is cooled and become dimensionally stable. It is during this time that the next shot is metered.