High Precision Injection Molding Manufacturer

Professional Precision Injection Mold Manufacturer

Precision injection molding is a type of plastic molding and is the most expensive and complex mold design process on the market. Kemal engineering department is an excellent technical team with 14 experienced engineers who can quickly design drawings for products or standard mold structures quickly, also can direct production. 80% of our engineers having more than 10 years of experience in the injection moulding industry, the perfect combination of technical and practical experience in design and manufacturing is the guarantee of precision moulds.

Precision Injection Molding Parts

Precision injection molding is a method of producing injection molds with a dimensional accuracy of 0.01mm or less, usually between 0.02 and 0.005mm in size.

Kemal has a precision injection molding workshop as well as a clean room workshop. Machine tonnage ranges from 60 tons to 200 tons to ensure the quality of the product during the production process. Mainly used in aerospace, auto parts, medical parts, gear parts, electrical connectors, precision instruments, sports equipment, testing tools, and other industrial and civilian products.

Why choose Kemal Make Precision Injection Molding

For precision injection molding, Kemal combines expertise in design for manufacturability, from concept to high volume production, with extensive experience in comprehensive analysis and testing to evaluate and validate, design, and manufacture lighter, more durable precision parts.

For more than 20 years, Kemal has been serving the needs of customers worldwide for precision injection molds. As a trusted partner to leading brands, Kemal’s precision injection molding technology allows companies to remain competitive by manufacturing parts that meet consumer needs with high quality and efficiency. Please contact us to customize your precision injection molding tool, Kemal project engineers will oversee the entire process and provide regular updates and deliverables.

 

Contact Our Professional Team

Kemal Your Reliable Precision Injection Molding Manufacturer

As an expert in manufacturing solutions, Kemal has a global network of suppliers and leading technologies that combine expertise in design for manufacturability from concept to high-volume production and offer our customers a variety of ways to optimize the use of precision injection molding and the production of high-precision plastic parts. The requirements of our customers are of paramount importance to us at all times, which is why we have maintained our growth in a highly competitive marketplace. We believe that if we work together, we will be an asset to your company and your team.

You can enjoy global precision injection molding technical support for 365 days.

Call now for a quote!

More Questions You May Ask

What's the factors that affect creating the quality of precision molded parts ?

(1) Product tolerances.

(2) Material and shrinkage.

(3) Correct mold company

(4) Mold design, mold manufacturing, and cavity dimensional accuracy.

(5) Precision molding machines

(6) Correct and standardized operation

(7) Ambient temperature, humidity, and fluctuations of the product.

 

What's the advantages of the Precision Injection Molding ?
  • High strength
  • good dimensional stability
  • efficient production good vermicular resistance
  • wide range of environmental adaptation.

 

What’ s the Kemal service for precision injection molding ?

MoldFlow Analysis, a Viscosity Curve, a Cavity Balance Study, a Pressure Window

Characterization, a Gate Seal Time Study, and a Cooling Time Study.

What’s benefits of the Precision Injection Molding?
  • Efficient production
  • Enhance Strength
  • Feasibility of complex design products
  • Reduced cost
  • Increasing production efficiency
Send Your Inquiry Today

PRECISION INJECTION MOLDING: THE ULTIMATE FAQ GUIDE

As a professional Precision Injection Molding manufacturer with 24 years of experience. Kemal pays 100% passion to serve you well.
Here is the FAQ list of the precision Injection Molding. You could check any question about the Precision Injection Molding that you would like to know.

Such as :
What aspects do we need to control the precision of the product?
What are the requirements of precision injection molding for injection molding machines?
What are the factors that affect the dimensional accuracy of Precision Plastic products?

For further communication just feel free to Contact Kemal Team.

Here is the FAQ List:

1.What is Precision Injection Molding?
2.What are the characteristics of precision injection molding?
3.What aspects do we need to control the precision of the product?
4.What are the requirements of precision injection molding for injection molding machines?
5.What are the factors that affect the dimensional accuracy of Precision Plastic products?
6.What are the factors that affect the dimensional accuracy of Precision Plastic products?
7.What are the selection principles of injection molding precision molding materials?
8.What are the commonly used materials for Precision injection molding?
9.In injection precision molding, what are the factors that affect shrinkage?
10.What are the characteristics of precision injection molds?
11. What is the reason that precision injection molding machines must be high pressure?
12. What are the characteristics of precision injection machines in terms of control?
13. In the design of plastics precision injection molding, besides the general mold design, what should be considered in particular?
14. In the design of precision injection molding, what are the main factors affecting the shrinkage rate of the molding?
15. In the design of precision injection molding, how to prevent forming deformation?
16. How to reduce the mold making error?
17. How to reduce the error of mold precision?
18. What should be paid attention to in the design of the Precision Injection Mold?
19. What are the common molding defects in precision injection molding?
20. In the process of precision injection molding, what should be done when the precision products have the molding flash?
21. In the process of precision injection molding, what should be done when the precision products have the weld mark?

 

1.What is Precision Injection Molding?

Precision injection molding refers to the size of the molded injection products with high precision.
So that the use of a general injection molding machine, the conventional injection molding process is difficult to meet the requirements of an injection molding method.

2.What are the characteristics of precision injection molding?

The characteristics of precision injection molding are as below:

1)The dimensions of the parts are of high precision and small tolerance, that is, they have a high-precision dimension limit.

2)The product weight repeatability accuracy is high, requires day, month, year dimensional stability.

3)The mold material is good, rigid foot, cavity dimension precision, finish, and the positioning precision between the formwork is high.

4)Using a precision injection machine to replace the conventional injection machine.

5)Adopting a precision injection molding process.

6)Select materials suitable for high precision injection molding.

 

3.What aspects do we need to control the precision of the product?

The aspects we need to control the precision of the product are as below:
This requires strict control from material selection, mold design, injection molding process, operator’s technical level, and other four major factors.

 

4.What are the requirements of precision injection molding for injection molding machines?

The requirements of precision injection molding for injection molding machines are as below:

Precision injection molding machine requires that the product size precision is generally within 0.01 ~ 0.001mm. Many precision injection molding machines also require that the injection molding machine has high injection pressure and high injection speed.

It is required that the clamping system should be rigid enough and have high enough clamping precision. The clamping precision refers to the high uniformity, adjustability, stability, and repeatability of clamping force and the high position accuracy of clamping.

The pressure, flow rate, temperature, and measurement are required to be accurately controlled to the corresponding precision. Multistage or stepless injection is adopted to ensure the reproducibility of the molding process and the repeatability of the product size.

 

5.What are the factors that affect the dimensional accuracy of Precision Plastic products?

The factors that affect the dimensional accuracy of Precision Plastic products are as below:

1) Mold accuracy;
2) Forming a shrinkage rate;
3) The temperature, humidity, and fluctuation range of the environment in which the products are used

6.What are the selection principles of injection molding precision molding materials?

The selection principles of injection molding precision molding materials are as below:
1)High mechanical strength
2)Good dimensional stability
3)Good creep resistance
4) Wide range of environmental adaptability

7.What are the commonly used materials for Precision injection molding?

1)POM and carbon fiber reinforced (CF) or glass-reinforced (GF) such materials are characterized by good creep resistance, fatigue resistance, weather resistance, and dielectric performance, and are difficult to burn. Lubricants are added and easy to demoulder

2)PBT reinforced polyester with short molding time: PBT ≤ POM ≈ PA66≤ PA6.

3)PC and GFPC. Features: good wear resistance, increased rigidity after strengthening, good dimensional stability, weather resistance, flame retardant and good processing.

8.In injection precision molding, what are the factors that affect shrinkage?

There are four factors that affect the contraction: heat contraction, phase change contraction, orientation contraction, and compression contraction.

9.What are the characteristics of precision injection molds?

The characteristics of precision injection molds are as below:
Mold precision mainly depends on the mold cavity size accuracy, cavity positioning accuracy, or parting surface accuracy to meet the requirements. General Precision injection mold dimensional tolerance, should be controlled in the product dimensional tolerance less than 1/3.

Machinability and rigidity, in the mold structure design, cavity number should not be too much, and the bottom plate, support plate, cavity wall should be thick, in order to avoid parts in high temperature, high-pressure action under the occurrence of violent elastic deformation.

Product demoulding, the mold should try to take less cavity number, less and short runner and higher-finish than ordinary mold, this is conducive to demoulding.

Precision mold material, choose high mechanical strength alloy steel. The material of the mold cavity and runner shall go through strict heat treatment, and the material with high hardness (forming parts shall reach HRC52 or so), good wear resistance, and strong corrosion resistance shall be selected.

 

10. What is the reason that precision injection molding machines must be high pressure?

The reason that precision injection molding machines must be high pressure are as below :

1)To improve the precision and quality of precision products, injection pressure has the most obvious impact on the shrinkage rate of products forming. When the injection pressure reached 392MPa, the forming shrinkage rate of the product was almost zero. In this case, the precision of the product is only affected by mold control or the environment. Experimental results show that the mechanical strength increases by 3% ~ 33% after the injection pressure increases from 98MPa to 392MPa.

2)The wall thickness of the precision products can be reduced and the forming length can be increased. Taking PC as an example, the products of 0.2ー0.8 mm wall thickness can be molded with 177 mpa injection pressure in an ordinary machine, while the products of 0.15ー0.6 mm thickness can be molded with 392 mpa injection pressure in a precision machine. The ultra-high pressure injection machine can be made longer than the products.

2)Improving injection pressure can fully promote the efficacy of the injection rate. To achieve the rated injection rate, there are only two ways: one is to increase the system’s maximum injection pressure; The second is to improve screw parameters and length-diameter ratio. The injection rate of precision injection machines is high.

11.What are the characteristics of precision injection machines in terms of control?

1)High requirements for the repeatability (reproducibility) of injection molding parameters,
and multi-level injection feedback control should be adopted
2)Multi-level position control;
3)Multi-stage speed control;
4)Multi-stage pressure holding control;
5)Multi-stage back pressure control;
6)Multi-stage screw speed control.

12 In the design of plastics precision injection molding, besides the general mold design, what should be considered in particular?

1)In order to obtain the product with the desired dimensional tolerance, the appropriate tools for dimensional tolerance should be considered.

2)Take into account to prevent the formation of shrinkage fluctuations.

3)Take care to avoid forming deformations.

4)Take into account to prevent demoulding deformation. 5)Make the mold making error minimum.

6)Consideration should be given to preventing mold accuracy fluctuations6) to consider to prevent mold precision fluctuation.

 

13. In the design of precision injection molding, what are the main factors affecting the shrinkage rate of the molding?

1)Resin pressure,

2)Resin temperature

3)Mold temperature

4)Gate cross-sectional area,

5)Injection time

6)Cooling time

7)Product wall thickness

8)Enhanced material containing basin,

9)Orientation,

10)Injection speed.

These effects vary with changes in items such as resins and molding conditions.

14. In the design of precision injection molding, how to prevent forming deformation?

Forming deformation is caused by internal stress under uneven shrinkage, so it is necessary to prevent uneven shrinkage.In the case of circular gear with holes in the center of the gear,
a gate must be provided at the center. However, when there is a big difference in shrinkage rate between the flow direction and the vertical direction of the resin, ellipse will be generated.
When a higher accuracy of roundness is needed, the gate at 3 or 6 points should be set.

However, full attention should be paid to the balance of the gate.
When the side gate is used, the 3-point gate will increase the inner diameter of the cylindric product. In the case that the gate marks are not allowed on the outer surface and the end surface, less use of the inner multi-point gate uniformly can get good results.

15. In the design of precision injection molding, how to prevent the deformation of demoulding?

Precision products are generally small, thin wall thickness, some have a lot of thin ribs.
The design of the chess set must take into account that the pieces are not deformed and can be properly removed. For resins with low shrinkage.

When the molding pressure is high, it is necessary to pay attention to the products that are easy to stay in the mold cavity. When forming gear with resin with small shrinkage, the mold cavity of the gear part is best designed on the template of the ejector side.

When using the top pin, it is necessary to pay attention to the number of top pins without deformation and the top pressure position. A perforated gear requires a core pin, which should be set on the ejector side formwork to facilitate parallel ejecting during ejecting.

For horn-shaped products, a piercing die plate may be used for ejection to prevent deformation. Generally, the draft angle of precision products is small. In order to reduce the demoulding force, mirror processing is needed, and the direction of grinding must be the direction of the drawing die. Block cores for easy grinding should be set in the direction of drawing mold.

16.How to reduce the mold making error?

In order to maintain mold accuracy, high wear resistance is required,
for which quenching is required.
The precision of quenching die can be up to 0.01 mm by grinding machine and EDM machine.
It is necessary to pay attention to the increased wear of electrodes during red die machining of EDM.

17.How to reduce the error of mold precision?

To ensure the positioning of sliding parts in each cycle,
It is necessary to prevent the fluctuation of mold precision.
In order to maintain the accuracy of sliding parts, sliding parts should be worn by fire.
The sliding part of the side core should be fitted with a positioning part.

 

18.What should be paid attention to in the design of the Precision Injection Mold?

In the design of precision injection mold, in addition to the general mold design considerations, special consideration should be given to the following matters.

1)In order to get the desired dimensional tolerance of the product, the appropriate mold dimensional tolerance should be considered.
2)To prevent the formation of shrinkage fluctuation.
3)Avoid forming deformation.
4)Avoid demoulding deformation.
5)To minimize mold making errors.
6)To prevent mold accuracy fluctuations.
7) To maintain mold accuracy.

19.What are the common molding defects in precision injection molding?

1)Short shot
2)Spilt material flying edge
3)Surface blowhole
4) Flow mark
5)Silver bar wire
6) Weld mark
7)Black strips and charred
8)Bubble
9)Cracking and albinism
10)Bending deformation
11)Mold Adhesion
12)Shrinkage distortion
13)Vacuum hole

 

20.In the process of precision injection molding, what should be done when the precision products have the molding flash?

1)When the Insufficient mold closing force. It should use a larger injection molding machine instead.
2) When the pin hole or guide pin of the mold is seriously worn. Repair should be done by machining.
3) When there are foreign bodies and impurities on the closing surface of the mold. It should be cleaned.
4) When the mold temperature or injection pressure is too high. It Should be reduced appropriately.

21.In the process of precision injection molding, what should be done when the precision products have the weld mark?

1) When The temperature of melting material and mold is too low. The temperature of the barrel and the die should be raised.
2) When The gate location is not set properly. The gate position should be changed.
3) When High volatile content in raw materials or poor mold exhaust. It should Remove volatile substances from raw materials and improve the mold exhaust system.
4)The injection speed is too slow. It should be sped up appropriately.
5)When There is no cold material hole in the mold. A cold feed hole should be added.
6) There are foreign bodies and impurities on the cavity surface. Cleaning should be done.
7) Unreasonable design of pouring system. The filling performance of the gating system should be improved to make the molten material flow smoothly in the cavity.