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Technical document

How to achieve high-precision production through precision injection molding

2025-06-30 10:18:00 precision injection molding
In the current era of high-end and intelligent manufacturing, precision injection molding technology has become indispensable in electronics, medical, automotive, and other industries due to its ability to produce high-precision and high-performance plastic products. Achieving high-precision production requires coordinated optimization across materials, molds, processes, equipment, environmental conditions, and quality control.

1. Precise Control of Material Properties

1.1 Consideration of Shrinkage Rate and Stability

The shrinkage rate of materials directly affects the dimensional accuracy of products. For example, polyethylene has a shrinkage rate of 1.5%-3.6%, while polycarbonate only shows 0.5%-0.7%. Prioritize materials with low and stable shrinkage rates. Additionally, establish a strict batch inspection system for materials, testing key indicators such as melt flow rate and density to ensure consistency between batches.

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1.2 Pretreatment and Supplier Management

Hygroscopic materials like nylon require drying at 80-120°C for 4-8 hours to eliminate moisture's impact on molding. Collaborate long-term with reliable suppliers and conduct regular evaluations to ensure stable material supply.

2. Optimization of Mold Design and Manufacturing

2.1 Structural and Cooling System Design

For products with uneven wall thickness, set up reinforcing ribs rationally and optimize wall thickness distribution. Adopt conformal cooling technology to design water channels, which can increase cooling efficiency by 30%-50% and avoid deformation caused by uneven cooling.

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2.2 High-Precision Machining and Assembly

Utilize five-axis machining centers (positioning accuracy ±0.005mm) and other advanced equipment for precise mold machining. Combine polishing and hard chrome plating to reduce surface roughness. Strictly control mold assembly accuracy to ensure smooth opening and closing and precise component fitting.

3. Refined Regulation of Process Parameters

3.1 Temperature and Pressure Management

Set barrel temperatures according to material characteristics; for instance, maintain polypropylene at 200°C-240°C. Adjust injection pressure based on product shape and size: thin-walled products require high-pressure rapid filling, while thick-walled products need reduced pressure. Precisely control holding pressure and time to prevent shrinkage and sink marks.

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3.2 Speed and Screw Control

Adjust injection speed properly to avoid air marks and weld lines. Set screw rotation speeds according to materials; for example, keep polyoxymethylene at 30-60r/min to prevent poor plasticization or material degradation. Leverage simulation software like Moldflow for process parameter optimization.

4. Enhancement of Equipment Precision and Maintenance

4.1 Equipment Performance Requirements

The injection system of precision injection molding machines must ensure accurate injection volume (volume deviation within 20% of product tolerance), and the flatness of the clamping system's fixed platen should be maintained at 0.08 - 0.10mm to guarantee basic equipment accuracy.

4.2 Maintenance and Upgrades

Regularly clean, lubricate equipment, calibrate sensors, and replace worn components. Upgrade outdated equipment in a timely manner by introducing servo motor drive systems, which can improve response speed and control accuracy. Install equipment monitoring systems to continuously track operating parameters and prevent failures.

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5. Strict Control of Production Environment Factors

5.1 Temperature, Humidity, and Cleanliness Control

Equip production workshops with constant temperature and humidity systems, maintaining the temperature at 22°C±2°C and humidity at 50%±5% to minimize environmental impacts on product accuracy. For high-precision products in medical and optical fields, production should be carried out in ISO 7-class cleanrooms with air purification equipment and regular cleaning.

5.2 Vibration and Light Management

Locate workshops away from vibration sources and install vibration isolation devices when necessary. Avoid direct strong light exposure to equipment and products to prevent local overheating that may affect accuracy.

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6. Improvement of Quality Inspection and Feedback

6.1 Application of Inspection Equipment and Technologies

Employ coordinate measuring machines (accuracy ±0.001mm) to measure key dimensions, and use optical and electron microscopes to detect surface and internal defects. Introduce online inspection technologies such as laser scanning and machine vision systems for real-time monitoring and automatic alarms.

6.2 Data Management and Process Improvement

Establish a quality data management system and apply statistical process control (SPC) methods to analyze data. Monitor production stability, trace issues based on inspection results, and optimize materials, molds, or process parameters to form a closed-loop quality improvement mechanism.

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