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Injection Molding Material

Injection molding materials are the foundation in the industrial filed. Feman tooling working with advanced technologies provide solutions for many applications in the injection molding industry.

Feman tooling provides different kinds of plastic injection molding materials solutions. With years working in the injection molding industry, we see many different kinds of plastic injection molding materials and are familiar with that are based on our long-term experience and professional technical knowledges. We serve in the automotive injection molding, packaging injection molding, medical injection molding, home appliance mold, etc. And these industries apply with different injection material due to the varied technical requirements form the product.

In the following, Feman will list some of the common material we use the daily such as ABS, PP, POM, PC, PVC, PA66, PMMA. Also, there is another engineering material whose features have special properties.For example, as one of ABS plastic molding manufacturers, we provide high-quality  ABS plastic injection molding. This engineering material requires special processing during injection such as high percentage glass fiber material, high carbon fiber material, high temp. material, low temp. material, toxic gas raw material. And these final injection products may be used to the aviation field, smart home appliance field, national defense industry, special medical industry, etc. Let's get more to form the following.

Selecting the Right Material for Your Plastic Injection Molding

In the injection molding material marker, there may have thousands of materials. And even like normal ABS, it may perform differently due to the slightly variation of the composition form the chemical elements. To choose a right material for the products could make difference in the daily application. 

 Check the field of the products is used for and what exactly the position product stay in. According to the  physical and chemical properties to choose the right injection molding material. In the national resin market, choose form the big brand company is the smart decision to guaranteed the performance. 

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Packaging Plastic Injection Molding

Feman Tooling specializes in plastic & die casting plastic injection mold design and building, who offers full-service mold manufacturing including design, prototype samples making, plastic molding tools building, reversion & Modification, accessory JIG & Fixture, plastic mold production up to 250T capacity and precision components making.

 Injection molding packaging industry is under big demand for daily production, especially now under the COVID-19, the world is under huge pressure of packing goods. Feman tooling has its own advantages with the injection machine run 24 hours to meet the marketing requirements. More than just this, Feman is making good injection molding bottle caps products. Caps for bottles, caps for cosmetics, caps for packaging goods, etc. 

 Feman Tooling is ISO9001:2000 certified plastic injection factory. our business philosophy is to exceed our customers' expectations and fulfill complete satisfaction. It's the foundation to maintain a mature and long term relationship with our valuable customers. 

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Injection Mold Design

We do plastic injection mold design in China, along with plastic product design and development, and other tooling requirements. We offer a unique perspective in plastic injection mold and product design. Decades of injection mold design experience allow us to incorporate the "moldability" factor into our product designs and evaluations. 

 We can manufacture the injection mold as per your requests with competitive prices, as we have our own mold designers and injection mold factory in china. We would be very interested in discussing the possibilities of collaborating our design services with your manufacturing capabilities. 

 Plastic injection mold design is one of most important parts of a success mold making project, For each of mold project, we will call out an internal kick-out meeting to decide the part layout, runner design, gating way, ejection method, cooling layout, etc. These would allow us to always design your mold with all of our intelligence resources instead of just by a single mold designer. 

 Our injection mold design engineering technologies include: 

Pro/Engineer/UG (3D)

AutoCad (2D)

Moldflow analysis (Filling flow/Deform simulation)

Powermill&UG (CNC Programming)

 We provide DFM reports and give customers an overall view on manufacturability and part design with our experiences and professional knowledges, and we are able to predict the potential risks and come up with optimized solutions.

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How Much is Injection Mold Generally?

A customer contacted us by searching the plastic die mould manufacturers on the Internet and asked our customer service: "how much is the medical plastic die mould in general?" Generally speaking, if the structure is simple, the requirements are not too high, and the material is ordinary, the mold price will range from thousands yuan to tens of thousands yuan. As to the structure with higher requirements, the price will range from at least tens of thousands to even one hundred thousand.

 If you need to know clearly how much the plastic die mould of this product you want to mass produce is, the first thing you need to do is to design the 3D drawing of the product, and then write down your detailed requirements for this product, so that the plastic die mould manufacturer can evaluate the exact cost and cycle of mold opening for you. If the 3D drawing is not finished so fast, a sample of the product can also be provided, and a professional plastic die mould manufacturer like Feman Tooling Co.,Limited. can also evaluate the mold customization cost and molding cycle of the product for you.

 In conclusion, if you want to know how much the plastic die mould of the product you need to mass produce is, you need to provide the 3D drawing or sample of the product to the professional plastic die mould manufacturer to evaluate the cost!

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Home Appliance Plastic Injection Molding

With the improvement of people's living standards, we can see all kinds of home appliances around. For example, television, air-conditioner, washing machine, computer and etc. And now more and more smart home appliances appear with the development of the Internet and artificial intelligence. Modern people are under the trend of replacing a smart home appliance.

 Feman supplies appliance injection molding and has a close connection with home appliance tooling at a very early age and now has a unique skill in building the home appliance mold. High-quality products, good technical support, sound after-sales plastic injection moulding services and sincere attitude have been well appraised by new and old home appliance customers. Feman Tooling has a sound organization and a team of experienced and efficient employees! Adhering to the business philosophy of "High quality, short lead-time and best service", we sincerely welcome customers from all over the world to visit our company for mutual benefit, sincerity and pragmatism. People are the essence of cooperation. We never stop self-study and self-improvement. Honesty and trust play a very important role in Feman, and we will work hard together with our employees, customers, suppliers, cooperation factories for a brilliant future to provide high-quality home appliance mould. We are a dedicated happy team with industrious work and dedicated to providing high-quality china home appliance mould. Let's work together for the people's smart future. 

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Heat Treatment of Precision Plastic Injection

In the process of heat treatment, the precision plastic injection mold often produces deformation. In order to prevent this kind of problem, as long as we grasp the deformation law, analyze the causes, and adopt different methods to prevent the deformation of the mold, it can be reduced and controlled. In general, the following methods can be adopted to prevent the heat treatment deformation of precision injection mold.

 (1) Reasonable selection of materials: the micro deformation die steel with good material should be selected for the precision plastic injection mold, the mold steel with severe carbide segregation should be reasonably cast and carried out, and the large and non-casting mold steel can be treated with solid solution double refinement heat treatment.

 (2) The mold structure design should be reasonable, the thickness should not be too different, and the shape should be symmetrical. For the large deformation mold, we should grasp the deformation pattern and reserve the processing allowance. For the large ones, the combined structures of precision injection mold can be adopted.

 (3) The precision injection mold should be pre-heat treated to eliminate the residual stress in the process of mechanical processing.

 (4) Reasonably select the heating temperature and control the heating speed. For the precision injection mold, slow heating, preheating and other balanced heating methods can be adopted to reduce the heat treatment deformation of the mold.

 (5) Under the condition of ensuring the hardness of the mold, the pre-cooling, staged cooling quenching or warm quenching process of the injection mold should be adopted as far as possible.

 (6) For precision injection mold, vacuum heating quenching and cryogenic treatment after quenching shall be adopted as far as possible if the premise permits.

 (7) The precision of some precision and complicated dies can be controlled by pre-heating treatment, aging heat treatment, quenching, tempering and nitriding heat treatment.

 (8) When repairing sand hole, air hole, wear and other defects of mold, cold welding machine and other repair equipment with small heat influence shall be selected to avoid deformation in the repair process.

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Gas Assisted Injection Molding

Gas-assisted injection (injection) molding, also known as gas injection moulding process, is a new injection molding process . It is one of the most important developments in the injection molding industry since the advent of reciprocating screw injection machines. 

Gas-assisted injection molding process is an extension of injection molding,unlike 2 shot molding process. It is developed on the basis of injection molding technology and structural foam injection molding. it can also be considered as a composite of injection molding and hollow molding. In this sense, it can also be called "Hollow injection molding". The principle is to replace the resin pressure in the cavity with a relatively low-pressure gas during the pressure holding phase of the original injection molding. 

Gas-assisted injection, unlike unscrewing mold mechanism, can be achieved by simply adding an air supply device to the existing injection molding machine. The gas supply device is composed of an air pump, a high-pressure gas generating device, a gas control device, and a gas nozzle. The gas control device uses a special compressor to continuously supply gas, and is controlled by an electronic control valve to keep the pressure constant. There are usually 3 levels of pressure. A set of gas control device can be equipped with multiple injection molding machines.To achieve this, whole gas injectino moulding process required closely connections. 

 The gas generally used is nitrogen. Gas pressure and gas purity are determined by the shape of the molding material and product. The pressure is generally 5 ~ 32MPa, the highest is 40MPa. 

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Uscrew Injection Molding

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Unscrew injection molding, as its name implied, there is thread in the plastic part for easy assemble and connection with other screw parts. Unscrew mold design is common in our daily life as we can see the caps form our bottle. This is kind of a very basic and normal unscrew molding products. 

 The Introduction of Unscrewing Mould

 Unscrew molding is a very important form of injection molding. Unscrew mold manufacturing technology is becoming more and more mature. However, many mold factories cannot really master the technical essentials. The injection mold unscrewing mechanism have very strict requirements for the entire mold manufacturing and processing because of their assembly performance. Unscrew mold is divided into internal thread mold and external thread mold. Externally threaded molds can generally be realized by slider in the mold, but the precision is very high. Internally threaded molds generally require the cooperation of the core pulling structure.

 Our company specializes in manufacturing unscrewing mould. Years of industry experience have given us a deep understanding and knowledge of unscrewing mold. We have made many kinds of packaging lids, pipes, connectors. If you are looking for a real unscrew mold manufacturer, please choose us.We will serve you the best, high quality unscrewing mold mechanism and products. 

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Two Shot Injection Molding Process

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The cover material is injected above, below, around or inside the substrate during the two shot injection molding process to form a complete part. This process can be done through multiple injections or insert injection molding, usually using an elastomeric covering material. During the two shot injection molding process, the core must be moved or moved to another cavity, or alternatively, the core must be fed into another injection molding machine.

 Backlash, nozzle holes, air outlets and mold surface texture are key elements in the design of the two shot injection molding process.

 Backstop between substrate and cover material is critical to bonding effectiveness, progressive thinning or linting of the projectile cover material should be avoided. Cover material that is too thin can lead to weak bonds, delamination and crimping. Excellent backstop design should isolate the cover material from the substrate.

 Nozzle orifice design is equally important to the success of two shot injection molding. The ratio of runner length to wall thickness is the leading factor in the bonding process. Based on experience, the ratio should not exceed 150:1, and should be kept around 80:1 when developing two shot molding process.

 In order to minimize the flow, the nozzle holes should be located at the point of maximum wall thickness. When using TPE resin, the size of the nozzle orifice should be paid attention to. Materials such as TPU require large bore nozzles to accommodate high viscosity, material degradation should be prevented due to high shear. Materials such as SEBS require higher shear velocities for optimal flow rates, It is better to use a small bore nozzle at the beginning and adjust the nozzle size after the first sampling.

 As with the nozzle holes, the air outlet is an important factor in the bonding process. It is difficult to control the amount of air left, but if you don't know how to control it, the bond may not be strong enough, and there may be a furring phenomenon. The depth of the air outlet is extremely critical to preventing frizz. Depending on the viscosity of the covering material, the outlet depth should be between 0.0005 and 0.001 inch.

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Tool Building

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As a good reputation manufacturer in China, we here share the basic injection mold making process in our company: 

 1. Products design department provides product information to injection mold design department, injection mold designers complete cost analysis in two working days, and provide to R&D manager. 

 2. R&D department release "Mold Making Apply" to plastic injection mold design department after confirming the project. 

 3. Injection mold designers organize relevant personnel to review the project based on the product information, including product structure, mold structure, cooling system, runner, slag, venting, etc. in plastic injection molding process

 4. After evaluation, injection mold designers begin to design the plastic injection mold, including 3D drawing correction, 3D parting, mold parts assembly drawing, EDM drawing, electrode drawing etc., and organize relevant personnel to evaluate those drawings, then issue to plastic injection mold making department. 

 5. Injection mold makers evaluate and study the drawings, and order mold materials if there is no objection, otherwise, communicate with the plastic injection mold designers.

 6. Injection mold makers inspect the mold materials in time after the materials arrive to injection mold factory china, and arrange technicians to do locksmith works, including turning, grinding, milling, screw holes, water carrying hole, center hole, CNC roughing, etc. The technicians should pay attention to the precision of each right-angle sides, avoid empty of the center hole and each production base, roughing margin etc. Then outsource each mold part to heat treatment promptly.

 7. After heat processing, plastic injection mold maker must detect its hardness and metallurgical analysis. Generally, the core hardness 46-50HRC, for uniform distribution of 9 points, requiring its hardness differ is less than 2HRC. Metallurgical analysis should be done for the injection mold core prior to processing to make sure there is no segregation, scars, etc. 

 8. Electrode processing, there are fine and rough processing, fine male spark is 0.05-0.08, rough male spark is 0.2-0.3 (subject to the actual situation). Be sure to pay attention to each processing benchmarks, and detect electrodes after processing finished.

 9. Before finishing, must make right angle for the mold core, the vertical degree should less than 0.02 mm, finish degree 1.6.

 10. For line cutting, please note that all parts' base, enlarge 0.02mm for the insert hole and center hole as tolerance clearance, for non-standard thimble, the tolerance clearance is 0.04mm of the actual thimble size. 

 11. Mold core finishing, based on the benchmarks after making right-angles, typically leaves 0.02 mm die as a margin (without considering tool wearing).

 12. EDM processing, process according to the drawings' size, fine 0.05-0.08, rough 0.2-0.3 (subject to the actual situation), pay attention to the benchmarks in processing, for sparks processing, the leave a margin of 0.03-0.05 mm. 

 13. The runner surface must be polished to achieve Ra6 or Ra7 finishing, the surface does not allow spark or knife pattern to exist. 

 14. Before assembling the plastic injection molding parts, the mold maker must do a comprehensive inspection for all related parts to make sure everything is in a good condition, and do cleaning and anti-rust treatment. Then fill "Mold Inspection Summary" form.

 15. In tryout, injection mold designers, plastic mold makers and die casting workshop personnel should go to the site, making analysis and solution of abnormal in casting tryout, improving the plastic injection mold and die casting process according to the results, and fill "Mold Tryout Report".

 16. By 100-150 cycle time, the tryout products are defect-free, the production department make production schedule, the technicians track the production processes, and feedback yield to the plastic injection mold making department.

 17. After tryout, plastic injection mold making department apply for storage with the forms of "Mold Making Apply" and "Mold Making Inspection".

  We are ready and looking forward to cooperate with your next project, Contact Us Now, you will be satisfied to choose us as your partner in plastic parts manufacturing process.

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PVC Injection Molding

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Polyvinyl Chloride (PVC or Vinyl) is a high strength thermoplastic material widely used in applications, such as pipes, medical devices, wire and cable insulation...the list is endless. It is the world's third-most widely produced synthetic plastic polymer. 

 Polyvinyl Chloride can be injection molded just like other plastics but the inclusion of chlorine in the material complicates the process. This is because melted PVC can give off a corrosive toxic gas. Accordingly, shops need to be equipped with sufficient ventilation systems. Those that aren’t are likely to be hesitant to work with the material. Additionally, special corrosive resistant materials like stainless steel or a chrome plating are required for the mold tool during PVC plastic injection molding. Shrinkage in PVC tends to be between one and two percent but can vary based on a number of factors including material durometer (hardness), gate size, holding pressure, holding time, melt temperature, mold wall thickness, mold temperature, and the percentage and type of additives.

  Properties of PVC Injection Molding

General performance PVC resin is a white or light yellow powder with a relative density of 1.35-1.45. The hardness of the product can be added by PVC transparent board PVC transparent board. Adjust the number of plasticizers. Pure PVC has low water absorption and permeability.

 Thermal properties: The thermal stability of PVC is very poor. It begins to decompose at 140 ° C and the melting temperature is 160 ° C. The coefficient of linear expansion of PVC is small, and it is flame retardant, and the oxidation index is as high as 45 or more.

 Electrical properties: PVC is a polymer with better electrical properties, but due to its greater polarity, electrical insulation is not as good as PP and PE. Dielectric constant, dielectric loss tangent and volume resistivity are large, corona resistance is not good, generally suitable for low-voltage and low-frequency insulating materials.

 PVC Injection Molding Requirement

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Injection Molding Condition Value Unit for reference

 Drying Temperature 60-90 °C

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Drying Time 4.0-6.0 hr

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Suggested Moisture Content <=0.30 %

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Rear Barrel Temperature 160-180 °C

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Middle Barrel Temperature 170-190 °C

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Front Barrel Temperature 180-200 °C

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Nozzle Temperature 180-200 °C

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Mold Temperature 40-60 °C

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Prototype Samples Making

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Prototype samples of plastic injection molding products are basic working samples, mockups, models, or just simulations of actual products, and other forms (final products and variants) are developed on this basis.

 The main motivation for prototyping is to verify the design of the actual product. Sometimes, creating prototype samples is called implementation, because this is the first step in converting a virtual or conceptual design into an actual physical form.

 It is a preliminary version of the actual product developed for the following purposes:

 Verify plastic mold design,

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Introduce to investors or licensees

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Intellectual Property Protection,

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Eliminate the knots in manufacturing,

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Test and improve products.

 We could make a prototype sample while if it is necessary. Our products have good quality with competitive injection molding price, if you need plastic injection molding products, please contact us without hesitation.

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PP Injection Molding

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Polypropylene, abbreviated as PP, is a colorless, odorless, non-toxic, translucent solid substance. Polypropylene (PP) is a thermoplastic synthetic resin with excellent properties. It is a colorless, translucent, thermoplastic and lightweight general-purpose plastic. With chemical resistance, heat resistance, electrical insulation, high-strength mechanical properties and good high-abrasion processing properties, etc., this has made polypropylene quickly used in machinery, automobiles, electronic appliances, construction, textile, packaging , agriculture, forestry, fishery and food industry.

 In recent years, with the rapid development of China's packaging, electronics, automotive and other industries, it has greatly promoted the development of China's industry. And because of its plasticity, polypropylene materials are gradually replacing wooden products, and high strength and toughness and high wear resistance, which is same with  nylon made by our nylon  plastic injection molding, have gradually replaced the mechanical functions of metals.

  Properties of PP Injection Molding

Polypropylene is a non-toxic, odorless and tasteless milky white highly crystalline polymer with a density of only 0.90- "0.91g / cm3. It is one of the lightest varieties of all plastics. It is particularly stable to water and absorbs water in water. The rate is only 0.01%, and the molecular weight is about 81.15 million. The moldability is good, but because of the large shrinkage (1% to 2.5%), thick-walled products are easy to sag, and it is difficult to meet the requirements for some parts with high dimensional accuracy , Good surface gloss.

 PP Injection Molding Requirement

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Drying Temperature 60-90 °C

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Drying Time 2.0-6.0 hr

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Suggested Moisture Content <=0.20 %

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Rear Barrel Temperature 200-260 °C

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Middle Barrel Temperature 210-270 °C

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Front Barrel Temperature 220-280 °C

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Nozzle Temperature 230-290 °C

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Mold Temperature 20-90 °C

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POM Plastic Injection Molding

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POM injection molding, Polyacetal, also known as acetal or polyoxymethylene (POM), is a formaldehyde-based, semi-crystalline engineering thermoplastic containing the functional group of a carbon bonded to two -OR groups. Other names of POM are Polyformaldehyde, Polymethylene glycol, Polyoxymethylene glycol. It is 100% recyclable.

 POM resins are widely used in the production of precision plastic molding parts for applications demanding good dimensional stability and sliding properties. Some of them include: Automotive, Electrical & electronic, Industrial, Drug Delivery ect. 

 The polymer serves as an alternative to metals thanks to its low friction & wear characteristics and its excellent balance of mechanical and chemical properties.

 Properties of POM Injection Molding

The tensile strength of POM reaches 70MPa, the water absorption is small, the size is stable, and the gloss is better than nylon. POM is a highly crystalline resin, which is the toughest among thermoplastic resins. With heat resistance, bending strength, fatigue resistance strength are high, wear resistance and electrical properties are excellent. POM properties: specific gravity 1.43 performance values ??m.p. 175 ° C tensile strength (yield) 70MPa Elongation (Yield) 15% (at break) 15% impact strength (no notched) 108KJ / m2 (with a notch) 7.6KJ / m2

 POM Injection Molding Requirement

 Drying Temperature 60-80 °C

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Drying Time 2.0-6.0 hr

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Suggested Moisture Content <=0.20 %

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Rear Barrel Temperature 170-190 °C

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Middle Barrel Temperature 180-200 °C

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Front Barrel Temperature 190-210 °C

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Nozzle Temperature 200-220 °C

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Mold Temperature 40-80 °C

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PC Injection Molding

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PC is classified as a ''thermoplastic'', and the name has to do with the way the plastic responds to heat. Thermoplastic materials become liquid at their melting point (155 degrees Celsius in the case of Polycarbonat). A major useful attribute about thermoplastics is that they can be heated to their melting point, cooled, and reheated again without significant degradation. Instead of burning, thermoplastics is like Polycarbonate liquefy, which allows them to be easily injection molded and then subsequently recycled.

 PC is commonly used for plastic lenses in eyewear, in medical devices, automotive components, protective gear, greenhouses, Digital Disks (CDs, DVDs, and Blu-ray), and exterior lighting fixtures. 

 The PC injection molding, unlike pom injection, most often produces parts by polycarbonates and their blends. Since polycarbonate is highly viscous, it is usually processed at high temperature to reduce its viscosity. In this process, the hot polymer melt is pressed through into a mold with high pressure. The mold when cools, gives the molten polymer its desired shape and characteristics. This process is generally used to manufacture polycarbonate bottles, plates etc. Since polycarbonate is a poor-flowing plastic, wall thickness should not be too thin.

 Properties of PC Injection Molding

 Mechanical performance: high strength, fatigue resistance, dimensional stability, and small creep (also rarely changes under high temperature conditions);

1.Heat aging resistance: The enhanced UL temperature index reaches 120 ~ 140 ℃ (long-term outdoor aging is also very good);

2.Solvent resistance: no stress cracking;

3.Stability to water: easy to decompose under water at high temperature (use caution in high 4.temperature and high humidity environment);

5.Insulation performance: excellent (moisture and high temperature can also maintain stable electrical performance, is an ideal material for manufacturing electronic and electrical parts);

6.Dielectric coefficient: 3.0-3.2;

7.Arc resistance: 120s;

8.Form ability: injection molding or extrusion of ordinary equipment.

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Other Materials Injection Molding

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Other Materials Molding

Here we list some other materials for plastic injection molding parts.

PE, Polyethylene is a lightweight, durable thermoplastic with variable crystalline structure. It is one of the most widely produced plastics in the world. Polyethylene is used in applications ranging for films, tubes, plastic parts, laminates, etc. in several markets (packaging, automotive, electrical, etc.)

 Polystyrene (PS) plastic is a naturally transparent thermoplastic that is available as both a typical solid plastic as well in the form of a rigid foam material. PS plastic is commonly used in a variety of consumer product applications and is also particularly useful for commercial packaging, laboratory ware, automotive, and Electronics.

General Purpose Polystyrene (GPPS) and High Impact Polystyrene (HIPS) are probably the most commonly used PS resins for injection molding. GPPS is clear, but brittle (think of a CD jewel case) while HIPS is opaque and much less brittle.

 Acrylonitrile Styrene (AS) - A group of copolymers that have the transparency of polystyrene, but with improved resistance to solvents and stress cracking. AS is used in applications ranging for Electrical/Electronic Applications, Appliances, Construction Applications, Decorative Parts, Automotive Applications, Piping, Telecommunications, Industrial Applications, Non-specific Food Applications.

 Thermoplastic Polyurethane or TPU is referred to as the bridge between rubbers and plastics. The material appears rubber-like, which means it can be extremely flexible, durable and smooth to the touch. All these properties and compound versatility makes TPU widely used in many industries for coatings, components and customer goods. TPU exhibits high-performance properties if processed correctly through injection molding, the important factors are mold and nozzle temperature, pressure and plasticizing energy. If the plastic injection molding process or an object's design don't suit the material, it may cause damage and shrinkage of parts.

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insert molding

Insert molding process is kind of a special injection molding style in the traditional molding process. Now are wildly used in the injection industry. In our daily life that we can see many plastic products are produced together with the metal parts. The traditional way to achieve this, people first make the plastic parts, the metal parts that will be combined with the plastic parts by Laser, hot melting etc. This is a kind of tedious process and required huge manual works. With insert molding occurs, we no-longer worried about this process. Normally the metal parts will be put together into a mold on the injection machine. The metal parts will be hold inside the mold by some special structure or fixture and then will be molded together with plastic.

 Insert injection molding process is wildly used in many industries. Feman tooling is an expert making the insert molding. With years of injection experience we successfully making the products for many customers and is highly appreciated.

 https://www.dgfeman.com/insert-molding.html