Choosing the right type of plastic for the job is often critical. Supply Concepts can assist you based on the knowledge and track record we have compiled through many years in the injection moulding industry and in plastic part manufacturing. We process a wide selection of thermoplastic materials including PVC, Nylon, Polycarbonate, Noryl, Styrene, Polystyrene, Polypropylene & Acrylic. Injection moulding parts can range from 3 grams to 10,000 grams. Plants incorporate use of robotic assisted part picking, drying and packing to minimize overhead and deliver the lowest possible part cost. When choosing injection moulding suppliers, you can be confident that Supply Concepts will provide the best ratio of cost and quality with our Asia manufacturing operations.
EPR - ethylene propylene rubber
SBR - styrene butadiene rubber
EPDM - ethylene propylene diene monomer rubber
SAN - styrene acrylonitrile copolymer
SI - silicone
SMC - thermoset polyester sheet Moulding compound
TPE - thermoplastic elastomer
TPO - thermoplastic olefin
TPU - thermoplastic urethane
UF - urea formaldehyde
Polymers are commonly referred to by both their names and abbreviations. Commercial polymers are also frequently referred to by the trade names of their manufacturer.
ABS - acrylonitrile-butadiene-styrene terpolymer
BMC - thermoset polyester bulk Moulding compound
EVA - ethylene-vinyl acetate copolymer
LCP - liquid crystal polymer
PA - polyamide, commonly called nylon
PAN - polyacrylonitrile
PAS - polyarylsulfone
PBD - polybutadine
PBT - polybuylene terephthalate
PC - polycarbonate
PE - polyethylene see also:
HDPE - high density PE
LDPE - low density PE
LLDPE - linear low density PE
VLDPE - very low density PE
HMW-HDPE - high molecular weight HDPE
UHMWPE – ultra high-molecular-weight polyethylene
PEEK - polyetheretherketone
PEK - polyetherketone
PEI - polyetherimide
PES - polyethersulfone
PET - polyethylene terephthalate
PET-G - glycol modified PET
PI - polyisoprene
PS-b-PI - polystyrene/polyisoprene block copolymer
PI - polyimide
PK - polyketone
PMMA - polymethyl methacrylate, commonly called acrylic
PMP - polymethylpentene
POM - polyoxymethylene, commonly called acetal
PP - polypropylene
PPA - polyphthalamide
PPO/PPE - polyphenylene oxide, polyphenylene ether
PPS - polyphenylene sulfide
PS - polystyrene
EPS - expanded polystyrene
HIPS - high impact polystyrene
PSO,PSU - polysulfone
PTFE - polytetrefluoroethylene
PU,PUR - polyurethane
PVA - polyvinyl alcohol (sometimes used for polyvinyl acetate)
PVAc - polyvinyl acetate
PVC - polyvinylchloride, commonly refered to as vinyl
PVOH - alternate abbreviation for polyvinyl alcohol
This process utilizes high pressure nitrogen gas to produce hollow injection moulded components resulting in lower weight, shorter cycles and reduced visual sinking. Variants of this process include “external gas moulding” and “internal gas moulding”. These processes allow more design freedom and flexibility. It also allows discreet coring out of a thick product, thicker ribbing and can also eliminate sink marks.
This process is used in the manufacture of complex hollow items leaving a relatively uniform wall section. Water is used to displace polymer melt and provide the packing pressure during the cooling phase of the cycle. Typical examples; manifolds, elbows and water pipes.The suggested advantages of WAIM over GAIM are:
-Thinner residual wall thickness (RWT) - lower material usage.
-Higher cooling rate - particularly where water is circulated.
-Improved internal surface finish.
MIM is an advanced manufacturing process for forming small, complex, high-precision and high performance metal parts. It is a development of the traditional powder metallurgy (PM) process and has several key advantages. In the PM process, parts with undercuts or projections at right angles to the pressing direction cannot normally be directly made. The MIM process substantially removes this limitation.
Similar to injection moulding but with multiple extruders to produce a single component from two 2 or more different parent materials or colors. Typical applications are soft over-moulding to produce seals or ergonomic soft-touch handles. Examples are : screwdrivers, soft-grip handles, cup-holders and toothbrushes.
Thin wall moulding is defined as a wall thickness of less than 0.025 in (0.62 mm) or a flow length to wall thickness ratio of greater than 200. When compared to standard injection moulding, high melt flow materials are used (30-60 MFI) along with accumulator assist injection and higher injection speeds/pressures. Stack moulds are common.
Recent advances in miniature moulding technology has seen major growth in the area of micro moulding for electronics and medical applications.
Thermoplastic Injection moulding is the most widely used of all plastic processing methods. Injection moulding offers the lowest piece prices available, but tooling prices are generally the highest. The injection moulding machine reduces pelletized raw material into a hot liquid. This "melt" is forced into a cooled mould under tremendous pressure. After the material solidifies, the mould is opened and a finished part is ejected.
Thermoset injection moulding is similar to thermo-plastic injection moulding except that uncured thermoset resins are mixed, injected, and held in a heated mould until cured. As with thermoplastic moulding, the price per piece can be low, but the tooling prices are generally higher.
This method is typically used to create hollow parts; jars, bottles, containers, etc. Part prices for this style of plastic and rubber services are generally higher than injection moulded parts, but, lower than rotationally moulded parts. Tooling costs are moderate.
Rotational moulding uses hollow moulds filled with powdered resin. Low tooling costs and higher piece prices are typical of this process.
Compression moulding services use a slug of hard media pressed between the two halves of a heated mould. After being formed, the part is air-cooled. Both tooling and piece part prices are moderate.
Thermoforming plastic moulding uses sheets of pre-extruded rigid plastic as the feed material. These are heated horizontally and sucked down into hollow one-piece tools.
(Also referred to as In-mould decorating) Mainly used in injection moulding. Robotically placed individual pre-printed decorative labels are loaded during each machine cycle into the mould tool. To assist adhesion during the closing and material flow stages, the label and tool is electrostatic charged.
Plastic welding – various plastic welding processes are employed depending upon part geometry, size and polymer used. Ultrasonic welding, hot-plate welding, vibration welding, laser welding and spin welding can all be used.
Structural foam moulding is a term commonly used to describe components made by the injection moulding process that have a cellular core in which the outer surface is denser than the inner layers. The core of the moulding is of a honeycomb nature and less dense than the outer surface. Can also be referred to as microcellular injection moulding (MuCell). Applications include - Wine corks, Energy absorbing foam, low weight products, impact absorbing pads.
Some plastics, including nylons, will absorb moisture from the atmosphere, which alters their physical properties. Properties affected include brittleness and dimensional stability. Moisture absorption can be as high as 2% of a products weight. A pigment is often applied during the moisture conditioning process to identify treated parts.