Plastic injection molding and injection molding extrusion are two popular manufacturing techniques used in the plastics industry. Both processes involve injecting molten plastic into a mold to create a desired shape, but they differ in several aspects.
What is plastic injection molding?
Plastic injection molding is a manufacturing process that involves melting plastic pellets or granules and injecting them into a mold under high pressure. The plastic material is heated until it reaches a molten state and then forced into the mold cavity using a screw or plunger. Once the plastic has cooled and solidified, the mold is opened, and the final product is ejected.
The process of plastic injection molding begins with the design of the mold, which is typically made of steel or aluminum. The design of the mold is crucial as it determines the shape, size, and features of the final product. Once the mold is designed, it is loaded into an injection molding machine, where the plastic pellets are fed into a hopper and heated. The heated plastic is then injected into the mold cavity, where it takes the shape of the mold. After cooling, the mold is opened, and the finished product is removed.
Injection molding extrusion, on the other hand, is a manufacturing process that involves melting plastic pellets or granules and forcing them through a die to create a continuous profile. This process is commonly used for the production of pipes, tubes, and other linear shapes.
What is injection molding extrusion?
Injection molding extrusion is a variation of the traditional injection molding process, where molten plastic is forced through a die to create a continuous profile. The process is similar to traditional extrusion, where plastic pellets are melted and forced through a die to form a continuous shape, but with the addition of an injection molding stage.
The process of injection molding extrusion begins with the plastic pellets being fed into a hopper and heated until they reach a molten state. The molten plastic is then forced through a screw or plunger, which transports it to the injection unit. The injection unit then injects the molten plastic into the die, where it takes the shape of the die. After cooling, the finished product is cut to the desired length.
Differences between plastic injection molding and injection molding extrusion
1. Process
The main difference between plastic injection molding and injection molding extrusion lies in the process itself. In plastic injection molding, the plastic material is injected into a mold under high pressure to create a solid product. In contrast, injection molding extrusion involves the continuous production of a profile or tube by forcing the molten plastic through a die.
2. Mold design
The design of the mold is another significant difference between the two processes. In plastic injection molding, the mold is designed to create a specific shape, size, and features of the final product. The mold is typically made of steel or aluminum and can be complex, with multiple cavities to produce multiple parts in one cycle. In contrast, the die used in injection molding extrusion is a simple shape that determines the cross-sectional profile of the final product.
3. Production speed
The production speed of plastic injection molding and injection molding extrusion also differs. In plastic injection molding, the entire process takes place in cycles, where plastic is injected, cooled, and ejected. The number of cycles per minute depends on the size and complexity of the product being made. Injection molding extrusion, on the other hand, works on a continuous basis, with the plastic material being continuously fed into the die.
4. Products
Plastic injection molding and injection molding extrusion are used to produce different types of products. Injection molding is primarily used to create solid, complex-shaped products, such as toys, automotive parts, and household appliances. Injection molding extrusion, on the other hand, is commonly used for the production of pipes, tubes, and other linear shapes.
5. Materials used
The materials used in plastic injection molding and injection molding extrusion are similar, but they can differ in some cases. Most plastics can be used in both processes, but their properties, such as viscosity and melt temperature, may need to be adjusted. While both processes can work with a wide range of plastics, injection molding extrusion is better suited for producing larger products with thicker walls.
6. Cost
The cost of producing a product using plastic injection molding and injection molding extrusion can vary significantly. The cost of plastic injection molding is generally higher due to the complex molds used and the number of operations involved. In contrast, the cost of injection molding extrusion is usually lower as it involves simpler dies and fewer manufacturing steps.
7. Complexity
The complexity of the products produced using plastic injection molding and injection molding extrusion also differs. Injection molding is better suited for producing complex products with intricate details, while injection molding extrusion is more suitable for simpler, continuous shapes.
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What is the extrusion process for injection molding?
Extrusion moulding is used to form plastic or metal materials into a pre-defined shape. During the process, the material is melted and pushed through an extrusion moulding machine, forming a long, tube-like shape or rod. This is cooled and cut to the required length.
What is extrusion molding also known as?
Extrusion molding (also known as plastification extruding) is a process that the stack of powders or the green body in die is pushed out to assume another form of green body or other final product under pressure.