Large Part Injection Molding|Plastic Machine Experts

2024-04-03 14:46:44

Large or medium-part injection molding has emerged as a game-changer in the manufacturing industry, offering unparalleled efficiency and precision in the production of large-scale plastic parts. As experts in the field, we understand the importance of choosing the right equipment for your needs. We’ll delve into the world of large and medium injection molding, explore its benefits and applications, and help you navigate the world of large and medium injection molding machines.



What is Large Part Injection Molding?

Large-part injection molding refers to the process of manufacturing large plastic parts using Injection molding machines with high clamping forces. These machines are commonly rated by their "clamping force," measured in tons. This rating indicates the force needed to hold the two halves of the mold together during the injection molding process. Larger parts with greater surface areas require higher clamping forces to ensure that the mold remains securely closed during injection. As a result, machines rated as "large tonnage" typically have clamping forces of 500 tons or more. This enables them to effectively mold large parts with precision and efficiency, meeting the demands of various industries for oversized plastic components.


What Makes Large Parts Injection Molding Different From the Standard?

Injection molding for large parts presents several key differences compared to standard plastic injection molding. One primary distinction is the machinery used. While standard machines vary in tonnage or clamping pressure from as low as five tons to around 3,000 tons, large-part molding requires machines with significantly higher tonnage ratings.

These large-tonnage machines, typically exceeding 500 tons, demand substantial resources. They occupy a footprint of about 40 feet by 15 feet by 15 feet and are utilized for manufacturing intricate parts that would be impractical or impossible to produce with standard injection molding machines. Furthermore, the molds and parts' sheer size and weight require ample space for staging, packaging, and storage, making them less practical for many companies.

In summary, the key differences between plastic injection molding for large parts and standard plastic injection molding lie in the machinery used, the complexity of the parts produced, and the substantial resources required. Large-part molding machines are scarcer due to their specialized nature.


Determining If Your Part Requires a Large-Ton Machine

When determining if your part requires a large-ton machine for plastic injection molding, several factors should be considered. These include the size of the part, the polymer used, and the safety factor. The safety factor is an additional numerical percentage buffer added to the calculation to help eliminate the risk of defects in the final product. Experts recommend adding 10% to allow for this safety factor. A general rule of thumb for measuring the amount of tonnage needed for any given plastic being produced is 2-8 tons per square inch. For example, a 10" x 10" part (100 square inches x 2 tons/sq. in.) will require 200 tons. It's important to note that the larger the part, the more clamp force is needed to hold the two halves of the mold together during the injection process.

Other items considered are as follows:

  1. Part Size and Complexity: Large parts or those with complex geometries often require higher tonnage machines to ensure adequate clamping force.
  2. Material Type: Certain materials, such as high-strength plastics or those with high viscosity, may require higher clamping forces to properly fill the mold.
  3. Projected Annual Volume: If you anticipate a high volume of production, a large-ton machine may be more cost-effective in the long run due to higher efficiency and productivity.
  4. Quality Requirements: Parts requiring high precision or structural integrity may benefit from the stability and consistency provided by a large-ton machine.
  5. Mold Design: The design of your mold, including the number of cavities and the complexity of the parting line, can affect the required clamping force.
  6. Consultation: It's advisable to consult with injection molding experts or machine manufacturers to determine the most suitable tonnage for your specific part and production requirements.



Two-Platen Injection Molding Machines for Large Injection Molding

The two platen injection molding machine is a specialized type of molding machine that is particularly well-suited for medium and large-sized machines to produce large injection molding plastic products. It features a unique design with two platens, or large plates, that hold the mold halves together during the injection process. Unlike traditional machines that use a three-platen design, the two platen machine's compact and efficient design makes it ideal for molding large plastic products with precision and efficiency.

 Large Injection Molding

Further reading: What is injection molding machine? By clamping mechanism to choose injection molding machine model


Advantage of Two Platen Machine for Large Part Injection Molding

The two platen injection machine offers several advantages that make it particularly suitable for large injection molding projects. These advantages include:

  • Cost-Effectiveness: These machines typically have a simpler structure and lower maintenance costs compared to three-platen machines, making them a more economical choice for producing large parts in bulk.
  • Space Efficiency: Two-platen machines have a smaller footprint compared to three-platen machines of similar tonnage. This space-saving design is particularly beneficial for manufacturers operating in limited space environments, allowing them to maximize their production capabilities without compromising on floor space.
  • Energy Efficiency: The optimized design and reduced number of moving parts result in lower energy consumption, making them a more environmentally friendly and cost-effective option for large injection molding projects.
  • Suitable for Large Mold Sizes: Two-platen machines are well-suited for large mold sizes, making them ideal for producing large parts. If the mold size is compatible with a two-platen machine and the production volume justifies the investment, opting for a two-platen machine can significantly enhance production efficiency and quality.
  • Flexibility: Two-platen machines offer flexibility in mold sizes and configurations, allowing manufacturers to adapt to varying production requirements. This versatility makes them a versatile choice for a wide range of large injection molding applications.

Further ready: 2 Platen Injection Molding Machine vs 3 Platen


Key of Two Platen Machines in Huarong

At Huarong Company, we take pride in our innovative approach to two platen machine design, which has led to several patents optimizing the machine for maximum efficiency and performance. Our patented technologies include:

  1. The Suspended Tie-bar Bearing Module supports the tie-bar, reducing energy loss due to friction and effectively improving its natural sagging.
  2. The Patented Inner Supporting Sliding Module and the Patented Moving Platen Positioning Device allow sliding components to be quickly assembled for precise positioning.
  3. Customers are regularly alerted during the production cycle, prompting them to use an inspection jig and gauge to check the height of the moving platen center to prevent abnormal coaxiality of the two platens.
  4. The Optional Patented Tie-bar Disassembles Function can help overcome the inconvenience of installing and removing molds in factories with restricted heights. The detached tie-bar is located on the operation side of the machine, making it easier for operators to work.

Our commitment to innovation and excellence has been recognized by the prestigious Taiwan Excellence Award, which we proudly received last year for our two-platen machines. For more information about our award-winning machine and patented technologies, please visit our two-platen machine product page.

Further article: HUARONG is honored with the 2024 Taiwan Excellence Award!

Related product: Two Platen Machine – NRH Series



Large Part Injection Molding Application

Large injection molding finds application in a variety of industries, where the production of large plastic parts is essential. Some common applications of large injection molding include:

  • Automotive: Large injection molding is used to produce components such as bumpers, dashboards, and interior trim.
  • Aerospace: Large injection molding is used to manufacture components for aircraft interiors, including seating and cabinetry.
  • Consumer Goods: Large injection molding is used to produce items such as furniture, storage containers, and sporting equipment.



Plastic Machine Experts in Large and Medium Injection Molding

This comprehensive guide has provided you with valuable insights into the world of large and medium injection molding. As the leading plastic injection molding machine manufacturer, Huarong is committed to providing all our clients with precision, custom plastic injection molding services that deliver premium quality components. If you have any further questions or machine needs, please don't hesitate to contact Huarong.



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