Abtec and plastic injection molding are synonymous for high quality, dimensional accuracy and high tolerance plastic parts. For over 44 years, the experts at Abtec have been working closely with clients to develop, design, and manufacture high quality plastic injection molded parts and components. It is Abtec’s dedication to quality and customer satisfaction that has made us the world leader in plastic molded parts, components, assemblies, and complex intricate devices.
The Injection Molding Process
Injection molding is one of the most popular production methods due to its cost effectiveness, precision, and adherence to design parameters. Since its introduction, in the latter part of the first industrial revolution, injection molding has rapidly grown into an essential supplier of high quality and high tolerance parts. Abtec, in the middle of the 20th century, introduced its custom precision thermoplastic injection technologies and its team of experts, specialists and engineers. Founded on customer service and product quality, we have thrived and grown into the most respected plastic component supplier in the world.
Design Concept
As with every aspect of manufacturing, the injection molding process begins with a concept or idea that is engineered into a computer designed rendering using 3D design software. Over our 44 years of designing and producing high quality injection molded parts, we have gained the necessary experience, expertise, and training required for fast turnaround times in mold design.
During the design phase of the process, Abtec experts work with our clients to perfect and adjust the initial design to meet the parameters of the customer’s application. Our 3D software provides a graphic rendering of the workpiece, which makes it easy for the client to visualize and critique. The interchanges between Abtec customers and Abtec technicians is a critical part of the success of the production process. Every intricate detail and nuance is examined, changed, and discussed to ensure the quality of the final product.
Prototyping
An advancement in modern technology that combines computers with industrial equipment is additive manufacturing or 3D printing. Once Abtec engineers and their clients have agreed on the parameters of a customer’s concept, a prototype of the component is produced using additive manufacturing, a process that efficiently and accurately provides a physical prototype of the proposed item.
The process of additive manufacturing involves translating the CAD rendering of a design into G-codes that guide a 3D printer in creating the prototype, layer by layer. Every part of the design is presented in detail such that Abtec engineers and customers can examine the many features of a part.
The creation of a 3D model is a cost-effective method that enables Abtec to offer customers physical representations of their concepts and avoids the need to cast and tool an expensive mold. The speed of additive manufacturing is another aspect of Abtec’s dedication to quick turnaround times. Although computer renderings are helpful, having a working model to examine provides the Abtec engineering team and our customers the opportunity to ensure a design fits an application.
Making the Mold
Abtec engineer designing and prototyping are critical parts of injection molding and are the aspects of the process that guarantee its success. One of the outcomes of the thorough examination of a design is Abtec engineers’ development of the design for manufacturability (DFM), which ensures the most efficient and cost-effective method for producing a part.
The prototype and computer rendering are used to produce the injection mold that will be used to produce the final product. Abtec molds are made from tooled steel, a metal that is extremely durable and resilient, or aluminum that is sometimes used for economical purposes. The type of metal used to produce a plastic injection mold is dependent on the volume of parts to be produced, with aluminum being ideal for short production runs while tooled steel is durable enough to handle high-volume.
Special Abtec craftsmen work diligently, using design parameters, to shape and form a mold. The process requires exceptional skill to avoid any errors that could be damaging to the final product. During mold making, Abtec’s 100 years of experience in injection molding is critical and is the reason for our many years of success.
The halves of mold cavities are negative representations of the final product. They are precision machined and tooled to produce high tolerance and dimensionally accurate parts. The creation of injection molds is an old and time worn craft that is expertly completed by the technicians at Abtec. As with many of the attributes of Abtec, we are very proud of the craftsmen who produce our injection molds.
Plastic Injection
Plastic injection molding involves injecting a specific quantity of melted plastic resin into the injection mold, referred to as a shot. Great care is given to ensuring the amount of plastic in the shot covers every crevice and cranny of the mold. This part of injection molding is especially critical for plastic products that have intricate details and complexity. Abtec’s ability to manufacture these complicated plastic products is one of the reasons for our success.
Prior to the injection of plastic into the mold, the halves of the mold are tightly clamped to resist the force of the injecting of the shot. The clamps keep the mold sealed during the dwelling phase. The length of time plastic remains in the mold varies from a few seconds to a few minutes with varying injection pressure.
Inside the mold, the plastic cools and hardens after making contact with the surface of the mold. During cooling, the plastic takes the form and shape of the plastic part. The cooling phase is determined by the type of plastic and the wall thickness of the product. Abtec offers a multitude of different types of plastics for injection molding that include polyurethane, acrylonitrile, nylon, polyolefin, and several others. Each type offered by Abtec has specific properties and characteristics to meet the requirements of any application.
Ejection
After the part has sufficiently cooled, it is carefully ejected from the mold. The precision of the ejection process is critical to the plastic injection mold process. Abtec uses an ejection system that provides the correct amount of force to push the molded part out of the mold. As with every step of plastic injection molding, Abtec ejection systems are designed to ensure the integrity of the completed product. The force applied is equal to the stability and strength of the completed product.
The Abtec Difference
Abtec has the experience, know how, and talent to tackle any form of plastic injection process. Our team of professionals take on the greatest challenges to produce high-tolerance and high-quality plastic products. Our exceptional capabilities and exceptional expertise have made us the world leader in plastic injection molding. To learn more about what Abtec can do for you, contact us today or visit our FAQ page for answers to your questions.
