Capable Thin Wall Injection Molding Builder

Professional Thin Wall Injection Mold Manufacturer

Due to the fast running speed of this thin wall injection moulding tool, with cycle times sometimes reaching 4s, high quality mould design and mould construction is a key factor in the success of thin wall moulding, otherwise the mould will will be broken quickly Kemal's strong engineering skills and professional experience base will help to ensure excellent mold design for thin-wall molding. In addition, an effective measure is to properly train process technicians and managers in the precise science of thin-wall molding.

Thin Wall Injection Molding Parts

Thin-wall injection molding is not only suitable for light-weight food packaging. Through proper part design, analysis, and hot runner systems, it is also widely used in various injection molding industries such as automotive, medical, electronics, mobile, and others.

Kemal’s thin-walled plastic products are consistently favored by customers around the world.

Why choose Kemal Make Thin Wall Injection Molding

After more than 20 years of effort, Kemal is a leader in thin-walled injection molding. Our team of technicians and engineers focus on designing a high-tech, durable, and cost-effective thin wall injection molding system. At Kemal, we take a wide range of industrial and household products and make them into affordable, functional products. our team also designs, develops, tests, and manufactures functional parts that are then mass-produced. If you would like more information about thin-wall injection molding, please get in touch with us.

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Kemal Your Reliable Thin Wall Injection molds Manufacturer

Thin-wall injection molding reduces the weight and size of plastic parts, facilitates overall design and assembly, and reduces costs, which appreciated by many of our customers.

During 20 years of development, Kemal has formulated its own mold standards and strict mold manufacturing process. Each mold is managed by experienced engineers. Meanwhile, Kemal has many high precision equipment, such as high-speed CNC, high-precision WEDM, high-precision EDM, and CMM, to ensure product accuracy; our knowledge, equipment, and process are the key factors for the successful production of thin injection molding.

Contact us to find out how we can help you with your thin wall injection molding. You can also take advantage of 24*7 start-up and technical support worldwide.

 

More Questions You May Ask

1. What’s Benefits of Thin wall Parts?

(1) Cheap and safe

(2) Packaging design options diversity

(3) Fast production speed and high productivity.

(4) Fewer materials and cost-saving

What's the challenges of Thin wall Injection Molding?

The injection mold needs to be strong enough to withstand high cavity pressures, clamp tonnages, and production rates. the mold cooling system design must be optimized so that heat is extracted quickly.

Which industries are using thin wall injection molding

(1) Food Packaging

(2) Automobiles

(3) Plastic cover

(4) Medical devices

(5) Plastic containers and caps

(6) Plastic packaging for consumer goods

(7) Electronic housing and protection

(8) Mobile communication and hand-held device components

What are the requirements for thin wall products?
  • high impact strength
  • good appearance quality
  • dimensional stability
  • can withstand large static loads
  • molding materials should have good fluidity.
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THIN WALL INJECTION MOLDING: THE ULTIMATE FAQ GUIDE

As a professional thin Wall Injection Molding manufacturer with 24 years of experience. Kemal pays 100% passion to serve you well.
Here is the FAQ list of the thin Wall Injection Molding You could check any question about the Prototype thin Wall Injection Molding that you would like to know.
Such as:
What are the molding conditions for thin-wall injection molding?
What are the characteristics of thin-wall injection molding products?
When the injection molding of large thin wall plastics parts occurs under injection, how to solve it?

For further communication just feel free to Contact Kemal Team.

Here is the FAQ List:

1.Why do clients prefer Thin Wall Injection Molding?
2.What are the advantages of Thin Wall Injection Molding?
3.What is Thin Wall Injection Molding?
4.Why the stability of thin-walled injection molding machines is so important?
5.How to choose the plastic material of thin-wall injection molding?
6.What are the points for attention when using thin- wall injection mold?
7.What are the molding conditions for thin-wall injection molding?
8.What are the characteristics of thin-wall injection molding products?
9.When the injection molding of large thin wall plastics parts occurs under injection, how to solve it?
10.What are the main points of product design for thin-wall injection molding?
11. When the thin-wall injection molding products have a vacuum hole, how to solve it?
12. When thin-wall injection molding, the occurrence of runner shrinkage, how to solve?
13. What to do when weld lines occur in thin-walled injection molding?
14. When flow marks occur in Thin Wall Injection molding, what should be done?
15.When the thin wall injection molding product surface has silver silks? How to adjust?
16.When discoloration occurs on the surface of thin-wall injection molded products, how to avoid it?
17.How to avoid thin wall injection molding shrinkage marks?
18.How to avoid peeling and delamination in thin-wall injection molding?
19.How to avoid warping deformation during thin-wall injection molding?
20.In thin-wall injection molding, the size of the product is not stable. What should be done?
21.In the thin wall injection molding, the product demoulding is not good, what should we do?

1.Why do clients prefer Thin Wall Injection Molding?

Because the cost of plastic raw materials usually accounts for a large proportion of the cost of products, such as 50-80%. Thin Wall Injection Molding helps to reduce the cost ratio.
With the miniaturization and portability of consumer electronic devices such as mobile phones, MP3 players, digital cameras, and pocket computers, the plastic design of these products has become increasingly Thin.

2.What are the advantages of Thin Wall Injection Molding?

The advantages of Thin Wall Injection Molding are as below:
Thin-walled products can reduce the quality and size of the product. Facilitate integrated design and assembly, shorten the production cycle, save materials, and reduce costs.

3.What is Thin Wall Injection Molding?

1)The flow length to thickness ratio is L/t, that is, the flow length L to the farthest point of the cavity that must be filled from the melt into the mold and the corresponding average wall thickness t ratio of 100 or more is called thin-wall injection.

2)The injection molding method is that the thickness of the plastic part is less than 1mm and the projection area of the plastic part is more than 50cm square.
The wall thickness of the molded part is less than 1mm or 1.5 mm.

4.Why the stability of thin-walled injection molding machines is so important?

1)The stability of the injection molding machine can control the weight of the product very well.
2) In the production process, the production can be stable to reduce the number of defective products.
3) Improve production efficiency.

 

5.How to choose the plastic material of thin-wall injection molding?

1)The selection of materials is the key to the forming of products.
2)Select materials according to the thickness of the product.
If the product is slightly thicker, the material with less fluidity can be selected; on the contrary,
if the wall is thin, the material with better selectivity can be selected.
3) General products can choose more than 60 melt numbers, too thin products can choose a higher melt number of materials.
4) When the melting amount of the material does not meet the requirements, the flow agent can be added accordingly. But the product with the fluid agent will become brittle and may not reach To the customer’s request.

6.What are the points for attention when using thin- wall injection mold?

1)Observe and understand the mold structure before loading the mold.
2)When opening and closing the mold, pay attention to whether the gate has cold material overflow, not only the overflow of cold material will cause mold gate pressure deformation and fracturing.

7.What are the molding conditions for thin-wall injection molding?

1)Temperature: Generally, the temperature of slightly thick products can be controlled around 260, while the temperature of products that are too thin can be controlled between 280-300. Increasing the temperature mainly enhances the fluidity of materials.

2)Pressure can be selected according to the size of the product pressure, generally between 65 and 100.

3) Product core deviation can be slightly deviated according to the degree of core deviation, if the core deviation is serious, only mold repair.

8. What are the characteristics of thin-wall injection molding products?

Thin-wall injection molding products require high impact strength, good appearance quality, and dimensional stability, as well as precise dimensional tolerances, and can withstand large static loads.

9.When the injection molding of large thin wall plastics parts occurs under injection, how to solve it?

1)When the melting temperature is too low. The temperature of the barrel and nozzle should be raised appropriately. The nozzle hole is blocked. It should be removed.

2)When Injection pressure is too low. It should be raised appropriately. The injection speed is too slow. It should be appropriately accelerated. The injection and holding time is too short. It should be extended appropriately.

2) When the insufficient material supply. The supply quantity should be increased.

3)When it is low screw back pressure. It should be appropriately increased.

(8) When it is the improper setting of the gate. The number of sprues and the section area of sprues should be increased appropriately.

(9)When it is the mold exhaust bad. It should increase the die exhaust.

(10)When it is insufficient mold strength. The mold rigidity should be improved as much as possible.

(11)When it is the Mold temperature is too low. It should be raised properly.

10. What are the main points of product design for thin-wall injection molding?

1) The design key points of thin-walled plastic parts are small wall thickness, but must meet the impact strength, appearance quality, and dimensional stability of the product, as well as the tolerance of precise size, and can withstand large static load requirements.

2)The rigidity, impact resistance, and manufacturability of plastic parts must be considered in the design process.

3)Because the thin-wall injection mold cavity is very narrow and the resistance of melt filling is large, sharp corners should be avoided in the design of plastic parts to reduce perforation.

4)The thin wall injection molding process uses a higher pressure, which limits local shrinkage
and allows for a thicker stiffener design.

4)When the wall thickness is less than 1.00 mm, the rib can be as thick as the wall thickness.

5)Because the shrinkage of thin-walled plastic parts is small, the drafting of reinforcing rib, Boss, and edge should be increased.

7)  Since the bending stiffness is inversely proportional to the cubic degree of the wall thickness, the thinner the part is, the worse the stiffness will be. The thinner the part.

8)The easiest way to increase the stiffness of plastic parts is to use fiber-filled reinforcement.

9)Clamp, Screw, Ultrasonic welding, and bichromatic injection molding on the assembly to hold the plastic parts together as tightly as a single part.

 

11.When the thin-wall injection molding products have a vacuum hole, how to solve it?

1)When it is the poor drying of raw materials. Further pre-drying should be done.

2)When it is the injection pressure is too high. It should be reduced appropriately.

3)When it is the injection speed is too fast. It should be appropriately slowed down.

4)When it is the mold exhaust bad. It should increase the die exhaust.

5)When it is the temperature of the cylinder is too high. It should be properly lowered.

6)When it is the mold temperature is on the low side. It should be raised appropriately.

7)When it is the screw back pressure is too low. It should be raised properly.

8)When it is the foreign matter and impurities are mixed into the raw material. Removal or replacement of raw materials shall be carried out. The screw speed is too fast. It should be reduced properly.

12. When thin-wall injection molding, the occurrence of runner shrinkage, how to solve it?

1)When it is an insufficient supply. The quantity of feed should be increased.

2)When it is the injection pressure is too low. It should be raised appropriately

3)When is the temperature of the cylinder is too high. It should be properly lowered.

4)When is the mold temperature is too low. It should be raised properly.

5)When it is the injection speed is too fast. It should be appropriately slowed down.

6)When it is the holding time of injection is too short. It should be appropriately shortened and prolonged.

13.What to do when weld lines occur in thin-walled injection molding?

1)When is the melting temperature is too low. The barrel temperature should be raised properly.

2)When it is the injection pressure is too low. It should be raised appropriately.

3)When it is the insufficient material supply. The quantity of material supplied should be increased.

4)When it is the poor drying of raw materials. Further pre-drying should be done.

5)When it is the injection and holding time is too short. It should be extended appropriately.

6)When it is the mold exhaust bad. Should increase the mold exhaust.

7)When it is the improper gate setting. The number of gates and the section area of the gate should be increased appropriately.

14.When flow marks occur in Thin Wall Injection molding, what should be done?

1)When the injection speed is too slow or too fast. It should be adjusted appropriately.

2)When it is the poor drying of raw materials. Further pre-drying should be done.

3)When the temperature of the cylinder is too low. It should be raised appropriately.

4)When the improper gate setting. The number of gates and the section area of the gate should be increased appropriately.

5)When the insufficient screw backpressure. It Should be appropriately increased.

6)When the mold exhaust bad. Should increase the mold exhaust.

7)The foreign matters and impurities are mixed into the raw materials. They should be removed.

15.When the thin wall injection molding product surface has silver silks? How to adjust?

1)When the melt temperature is too high. It should be properly reduced.
2)When the mold temperature is too low. It should be raised properly.
3)When the foreign matters and impurities are mixed into the raw materials.
They should be removed.
4)When the poor drying of raw materials. Further pre-drying should be done.
5)When the mold temperature is too low. It should be raised properly.
6)When the injection speed is too fast. It should be appropriately slowed down.

 

16.When discoloration occurs on the surface of thin-wall injection molded products, how to avoid it?

1)When the injection speed is too fast. It should be appropriately slowed down.
2)When the screw back pressure is too high. It Should be appropriately reduced.
3)When the mold exhaust bad.  Should increase the mold exhaust.
4)When the screw speed is too fast. It Should be appropriately reduced.

17.How to avoid thin wall injection molding shrinkage marks?

1)When the injection pressure is too low. It should be raised appropriately.
2)When the injection speed is too slow. It should be appropriately accelerated.
3)When the insufficient material supply. The quantity of material supplied should be increased.
4)When the improper gate setting. The number of gates and the section area of gates. It should be increased appropriately.
5)When the mold temperature is too low. It should be raised properly.
6)When the injection and holding time is too short. It should be extended appropriately.
7)When the nozzle hole clogging. It Should be removed.

18.How to avoid peeling and delamination in thin-wall injection molding?

1)When the injection pressure is too high. It should be reduced appropriately.

2)When the barrel temperature is too high. The barrel temperature should be properly reduced.

3)When the injection speed is too fast. It should be appropriately slowed down.

4)When the mold temperature is too high. It should be properly lowered.

5)When the uneven or insufficient cooling. The cooling time should be extended or the product should be cooled in the mold.

6)When the screw speed is too fast. It Should be appropriately reduced.

7)When the dosage of the mold release agent is too much. It should be reduced appropriately.

8)When the nozzle hole clogging. It Should be removed.

9)When the foreign matter and impurities are mixed into the raw material. It should be wiped out completely.

 

19.How to avoid warping deformation during thin-wall injection molding?

1)When the improper gate setting. The number of gates and the section area of the gate should be increased appropriately.
2)When the uneven or insufficient cooling. The cooling time should be extended or the product should be cooled in the mold.
3)When the injection pressure is too high. It should be reduced appropriately.
4)When the injection speed is too fast. It should be appropriately slowed down.
5)When the melt material temperature is too high. Properly reduce the temperature of the barrel.
6)When the mold exhaust bad. It should increase mold exhaust.
7)  When the screw back pressure is too high. It should be appropriately reduced.

20.In thin-wall injection molding, the size of the product is not stable.

What should be done?

1) When the melt temperature is too high. The temperature of the barrel should be reduced appropriately. However, it should be noted that if the melt temperature is too low, it will also cause dimensional instability.
2) When the injection pressure is too low. It should be raised appropriately.
3) When the injection and holding time is too short. It should be extended appropriately.
4) When The poor drying of raw materials. Further pre-drying should be done.
5) Improper mold temperature control. If the mold temperature is too high or too low will cause dimensional instability, It should be appropriately adjusted.

21.In the thin wall injection molding, the product demoulding is not good, what should we do?

1)When the temperature of the cylinder is too high. It should be properly lowered.

2)When the improper material supply. The quantity of material supply shall be adjusted reasonably.

3)When the injection pressure is too high. It should be reduced appropriately.

4)When the injection speed is too fast. It should be appropriately slowed down.

5)When the injection and holding time is too long. It should be shortened appropriately.
insufficient cooling. The cooling time should be extended appropriately.