Plastic Moulders UK Article | Demystifying Part Warp: Analysing Pressure Gradients, Polymer Temperature, and Their Effects

Posted on September 13, 2023September 13, 2023 by Peter Wilkinson

Plastic Moulders UK Article | Demystifying Part Warp: Analysing Pressure Gradients, Polymer Temperature, and Their Effects on Residual Shear Stress and Shear Rate

The following article is from Ledwell Plastics, Plastic Moulders UK

When it comes to the manufacturing of plastic parts, one of the most common challenges faced is part warp. The phenomenon of part warp can be frustrating and costly, often resulting in rejections, rework, and even production delays. However, by understanding the underlying factors that contribute to part warp, such as pressure gradients and polymer temperature, manufacturers can take proactive measures to prevent or minimise this issue. In this blog post, we will delve into the intricate details of part warp, exploring its causes and effects on residual shear stress and shear rate. By demystifying these complex concepts and providing practical insights, we aim to equip manufacturers with the knowledge and tools necessary to effectively address part warp and ensure the production of high-quality plastic parts.

1. Understanding part warp: Causes and consequences

Understanding part warp is crucial in the manufacturing process, as it can have significant consequences on the final product’s quality and performance. Part warp refers to the distortion or deformation that occurs in a plastic component during the cooling process after moulding. It is a commonly encountered issue that can lead to dimensional inaccuracies, poor aesthetics, and even functional problems. Several factors can contribute to part warp, with pressure gradients and polymer temperature being two key influencers. Pressure gradients occur when there is an uneven distribution of pressure within the mould cavity during the injection moulding process. This can result from variations in material flow, gate design, or the filling pattern. High-pressure areas can lead to increased material flow, resulting in excess poly

mer filling certain regions of the mould cavity faster than others. Conversely, low-pressure regions can cause insufficient filling, leaving voids or thin sections. These imbalances in material distribution can lead to uneven cooling rates, which ultimately result in part warp. Polymer temperature also plays a crucial role in part warp. During the cooling phase, the polymer undergoes thermal contraction, which can cause distortion if not uniformly controlled. If sections of the part cool faster than others, thermal stresses build up and can cause warping. Factors such as material composition, mould design, and cooling mechanisms can influence polymer temperature distribution. The consequences of part warp can vary depending on the specific application and requirements of the component. It can result in dimensional variations, making the part incompatible with assembly or causing functional issues. Aesthetically, part warp can lead to visible deformities, surface defects, or even part failure. Understanding the causes and consequences of part warp is essential for manufacturers to implement effective mitigation strategies. This involves careful design considerations, including gate placement, mould design optimisation, and material selection. Additionally, controlling process parameters such as injection pressure, melt temperature, and cooling rate can help minimise the occurrence of part warp. By addressing pressure gradients and polymer temperature distribution, manufacturers can strive to produce high-quality components with minimal distortion and ensure optimal performance and customer satisfaction.

2. Pressure gradients: A key factor in part warp

When it comes to part warp in the manufacturing of plastic components, pressure gradients play a crucial role. Understanding and analysing pressure gradients can help demystify the causes behind part warp and provide insights into effective mitigation strategies. Pressure gradients refer to the variation in pressure experienced across different sections of a mould during the injection moulding process.

These variations can arise from a multitude of factors, including variations in polymer temperature, flow rate, and the design of the mould itself. The uneven distribution of pressure within a mould can lead to uneven cooling and solidification of the molten polymer, resulting in part warp. The variations in pressure can cause different rates of cooling and shrinkage across the part, leading to distortions and deformations. Analysing and managing pressure gradients is essential to minimise part warp. One effective approach is to optimise the design of the mould by incorporating features that promote uniform pressure distribution. This can include the strategic placement of cooling channels, the use of venting systems to release trapped air, and the implementation of proper gate design. Furthermore, careful monitoring and control of polymer temperature during the injection moulding process can help mitigate pressure gradients and minimise part warp. Maintaining consistent temperature throughout the mould cavity ensures uniform cooling and reduces the likelihood of uneven shrinkage. It is also important to consider the shear stress and shear rate experienced by the polymer during the injection moulding process, as they can influence pressure gradients and subsequently affect part warp. High shear stresses and rapid shear rates can result in non-uniform polymer flow, leading to uneven pressure distribution and subsequent part distortions. By understanding the correlation between pressure gradients, polymer temperature, residual shear stress, and shear rate, manufacturers can take proactive measures to mitigate part warp and enhance the overall quality of their plastic components. In conclusion, pressure gradients are a key factor contributing to part warp in the injection moulding process. Analysing and managing these gradients, along with considerations of polymer temperature, shear stress, and shear rate, can help manufacturers effectively address and minimise part warp issues, leading to improved product consistency and customer satisfaction.

3. Polymer temperature: Its impact on part warp

Polymer temperature plays a crucial role in the phenomenon of part warp. Understanding how it impacts the warping of plastic parts is key to achieving high-quality, dimensionally stable products. When a polymer is heated, it undergoes thermal expansion, causing it to expand in size. As the polymer cools down, it contracts, returning to its original dimensions. However, if the cooling process is not uniform or controlled properly, residual stresses can accumulate within the material, leading to part warp. The temperature at which the polymer is processed and cooled significantly affects the degree of part warp. If the cooling rate is too rapid, temperature gradients can form within the material, causing uneven contraction and resulting in warping. On the other hand, if the cooling rate is too slow,

the polymer may remain at elevated temperatures for an extended period, leading to excessive relaxation and potential warping as well. To mitigate part warp caused by improper temperature control, it is crucial to monitor and control the cooling process carefully. This can be achieved through techniques such as adjusting cooling rates, using cooling fixtures, or employing cooling media to facilitate uniform temperature distribution. Additionally, optimising the mould design and incorporating cooling channels can help regulate the polymer’s temperature and minimise temperature gradients. Furthermore, it is important to consider the polymer’s specific thermal properties during the processing stage. Different polymers have their own unique thermal behaviours, including their coefficient of thermal expansion and glass transition temperature. Understanding these properties and adjusting the processing conditions accordingly can help minimise part warp. In conclusion, the temperature at which a polymer is processed and cooled plays a significant role in part warp. By carefully controlling and monitoring the cooling process, selecting appropriate materials, and optimising mould design, manufacturers can minimise the effects of temperature gradients, reduce residual stresses, and achieve high-quality, dimensionally stable plastic parts.

4. Analysing residual shear stress and shear rate

When it comes to understanding part warp in manufacturing processes, analysing residual shear stress and shear rate is crucial. Residual shear stress refers to the internal stress that remains within a material after it has undergone deformation. Shear rate, on the other hand, measures the rate at which adjacent layers of a material slide past each other. Analysing residual shear stress and shear rate can provide valuable insights into the underlying causes of part warp. High residual shear stress indicates that there is excessive internal stress within the material, which can lead to deformation and warping. By identifying and addressing the factors contributing to high residual shear stress, manufacturers can mitigate part warp issues. Similarly, studying shear rate helps in understanding the speed and intensity at which material layers are moving relative to each other. A high shear rate can result in uneven material flow and increased internal friction, both of which can contribute to part warp. By analysing shear rate, manufacturers can identify areas of the manufacturing process where adjustments may be needed to minimise shear-induced warping.

To analyse residual shear stress and shear rate, various techniques can be employed, such as numerical simulations, experimental testing, and rheological studies. Numerical simulations involve using advanced software to model and simulate the behaviour of materials under different conditions, allowing for the prediction of residual shear stress and shear rate. Experimental testing involves subjecting materials to controlled conditions and measuring the resulting residual shear stress and shear rate. This can be done through techniques like mechanical testing, thermal analysis, or microscopy. Rheological studies involve analysing the flow behaviour of materials, particularly their viscosity and elasticity, which are directly related to shear stress and shear rate. Rheological measurements can provide valuable data on how a material responds to different levels of stress, temperature, and deformation, aiding in the understanding of part warp mechanisms. By analysing residual shear stress and shear rate, manufacturers can gain a deeper understanding of the factors contributing to part warp and develop targeted strategies to minimise its occurrence. This knowledge can lead to more efficient manufacturing processes, improved product quality, and reduced waste, ultimately benefiting both manufacturers and customers.

We hope you have enjoyed our Plastic Moulders UK Article.

To find out more about injection moulding services please contact Benn Simms, benn.simms@ledwellplastics.com Managing Director of Ledwell.

Injection moulding near me | cost of Injection moulding

Posted on September 12, 2023September 13, 2023 by Peter Wilkinson

Injection Moulding Near Me | Overview of Injection Mould Cost

The first thing you need to know is: what companies are offering injection moulding near me?

Then you can contact them and delve into the costs associated with your project.

Determining the injection mould cost is not a straightforward task as it is subject to various factors. Considering all the variables involved is crucial in evaluating the overall cost of the injection mould. One must carefully weigh the cost of the mould against the number of parts being manufactured. Producing higher quantities of parts will result in a lower per-piece cost, as the total injection mould cost can be distributed over hundreds or thousands of pieces. Despite the initial expense, injection moulding remains the quickest and most cost-effective method for producing large quantities of plastic parts.

How to Calculate Injection Moulding Cost.

The cost of plastic injection mould tooling largely relies on the machining of the injection mould. Several factors come into play when determining the cost. The complexity of the mould is the key element in the cost of the tooling, the size of the mould is also a significant factor in its cost. Larger and more intricate moulds will naturally be more costly compared to smaller and simpler moulds. Additionally, the type of mould influences its price. Prototype injection moulds typically cost less than moulds used for production runs. On the other hand, moulds intended for long production runs will incur higher expenses. To withstand repeated use during extended production, these moulds need to be constructed from strong, high-strength, fully hardened steel, steel such as P20 or anti-corrosion stainless steel. How the part is going to be fed is an often-under-considered factor as well. This could be from a myriad of different cold feed options or if the need arises a hot feed may be necessary to suit your application. Gate vestige, gate size and plastic runner waste factor need to be considered so we understand what type of runner and feed is ideally suited to the product.

The number of injection cavities built into the mould is the final factor to consider. High-production moulds often have multiple, identical injection cavities, known as multi-cavity moulds. Meanwhile, family moulds feature two or more similar cavities that may not be identical. An example is moulds producing the right and left sides of a part that snap together. These moulds consist of multiple cavities that produce the same part or related parts in a single press, reducing the frequency of opening and closing the mould while enhancing production efficiency.

The following are some of the questions that will need answering to enable the best price solution for your project: –

How many products do you require per batch and per annum?
Do you know what material you may want to use, if not can you explain the function and ergonomic requirements of the product and we can offer advice?
Part colour, does this need to be a specific RAL colour, or colour-matched?
Expected total life for the product?
Do you have any specific tooling specification requirements?
What is the expected surface finish for the part?
Is the part design open for change to help us to offer you a cheaper longer lasting, better overall solution for the mould tooling?
Do the parts need to comply with any regulations, such as fire-retardant UV degradation?
Are there any other factors that may influence the parts going forward that may need to be considered?
Do you require prototypes?
Do you require design advice and help?

To find out more about injection moulding services please contact Benn Simms, benn.simms@ledwellplastics.com Managing Director of Ledwell.

Injection Moulding Plastics | The Importance of Testing and Validation in Injection Moulding Plastics

Posted on July 21, 2023August 26, 2023 by Peter Wilkinson

Testing and Validation of injection moulding plastics

Introduction

Injection moulding plastics is a widely used manufacturing process for creating plastic parts and products. To ensure the success of a project, it is crucial to implement thorough testing and validation methods. This article will delve into the significance of testing and validation in injection moulding plastics, exploring the various standards, regulations, tools, and processes involved. By understanding the importance of these practices, manufacturers can achieve greater efficiency, product integrity, and cost-effectiveness in their operations.

Understanding Testing and Validation

Testing and validation in injection moulding plastics involve the systematic evaluation of the manufacturing process and the final products to ensure they meet the required quality and performance standards. These processes help identify any potential issues, defects, or deviations from specifications, allowing manufacturers to make necessary adjustments and improvements. By validating the manufacturing process, manufacturers can create a stable and reliable production system that consistently delivers high-quality products.

Standards and Regulations

Standards and regulations play a crucial role in the testing and validation of plastic injection moulded products. Regulatory bodies vary from country to country. In the USA the FDA (U.S. Food and Drug Administration) and in the EU, the European Commission, have specific guidelines and requirements that manufacturers must adhere to. These guidelines ensure that critical aspects of the manufacturing operation are validated throughout the product lifecycle, including any changes that may impact product quality. Compliance with these standards is essential for gaining regulatory approval and maintaining product safety.

The Process Design Phase

The process design phase is an integral part of testing and validation in plastic injection moulding. During this phase, manufacturers evaluate the sizing and calibration of the equipment, such as the injection moulding machine. Proper calibration and equipment selection are essential to ensure the manufacturing process is optimised and capable of producing high-quality products. Manufacturers must carefully consider factors like shot size, tonnage, and machine settings to achieve the desired outcomes.

Process Qualification and Dimensional Studies

Process qualification involves establishing a range of process parameters that ensure the stability and consistency of the injection moulding process. Statistical and dimensional studies are conducted to identify any deviations or variations in the process that may impact the quality of the final product. This phase aims to validate that the variations are within acceptable limits and do not adversely affect the finished product. By conducting these studies, manufacturers can ensure that their products consistently meet the required specifications.

Continued Process Verification

Continued process verification focuses on demonstrating the long-term stability and consistency of the injection moulding process. Manufacturers simulate different production runs using the same equipment and processes to ensure repeatability and reliability. This phase is crucial for assessing the ongoing performance of the manufacturing process and identifying any potential issues or deviations. Regular monitoring and documentation of the injection moulding process are necessary to maintain compliance with ISO 13485 standards and other regulatory requirements.

Collaboration and Communication

Effective collaboration and communication between manufacturers, suppliers, and customers are essential for successful testing and validation in plastic injection moulding. Clear expectations and requirements must be established from the outset to ensure all parties are aligned. Manufacturers should work closely with their customers to understand the critical factors and performance criteria that need to be validated. By fostering open communication, manufacturers can address any concerns or challenges that may arise during the testing and validation process.

Tools and Technology

The use of advanced tools and technology greatly facilitates testing and validation in plastic injection moulding. Simulation software allows manufacturers to predict and optimise the moulding process before actual production. This technology helps identify potential issues, such as part warping or inadequate fill, enabling manufacturers to make necessary design modifications. Additionally, robotics and process control systems enhance the precision and efficiency of the moulding process, ensuring consistent quality and reducing the risk of defects.

Risk Management and Product Integrity

Risk management is a crucial aspect of testing and validation in plastic injection moulding. Manufacturers must identify and mitigate potential risks throughout the manufacturing process to ensure product integrity. This includes addressing changes in pressure, temperature, flow rate, and cooling rates, which may require re-validation exercises. By proactively managing risks, manufacturers can minimise the occurrence of defects, product recalls, and costly rework. It is essential to establish a robust risk management framework that encompasses all stages of the injection moulding process.

Benefits of Testing and Validation

Thorough testing and validation in plastic injection moulding offer numerous benefits to manufacturers. By implementing these processes, manufacturers can achieve greater levels of customer satisfaction, lower production costs, and increased profitability. Testing and validation help identify and resolve potential issues early in the manufacturing process, reducing the risk of delays and costly rework. Additionally, these processes contribute to the overall efficiency and reliability of the production system, ensuring the consistent delivery of high-quality products.

Conclusion

Testing and validation are critical components of the plastic injection moulding process. By following established standards and regulations, collaborating effectively, leveraging advanced tools and technology, and managing risks, manufacturers can ensure the quality and integrity of their products. Thorough testing and validation not only lead to regulatory compliance but also contribute to improved efficiency, reduced costs, and increased customer satisfaction. By prioritising testing and validation, manufacturers can achieve long-term success in the highly competitive world of plastic injection moulding.

To find out more about plastic injection moulding please contact Benn Simms benn.simms@ledwellplastics.com Managing Director of Ledwell

Injection Moulding Process – The Vital Role of Mould Temperature

Posted on July 21, 2023August 26, 2023 by Peter Wilkinson

Injection Moulding Process and Mould Temperature

Plastics Injection Mould Tool

Injection moulding is a popular technique in manufacturing, enabling the production of a vast array of components with intricate designs and diverse materials. Given the efficiency of the injection moulding process and its adaptability, it is used across numerous sectors, including automotive, electronics, and healthcare.

One of the most important aspects of injection moulding is mould temperature, this factor can significantly impact the quality of the production and the parts that are being produced. Effective temperature control is critical for preventing quality issues such as shrinkage, stresses and warping from developing in the plastic. It is important that a balance between temperature of the cooling fluid and the rate of mould cooling is controlled.

This article delves into the importance of mould temperature in the injection moulding process, exploring its influence on the various stages and the resulting outcomes.

Defining Mould Temperature

Mould temperature refers to the temperature of the mould surface itself. It is a crucial factor during the injection moulding process as it determines how the product heats up and cools down. This temperature fluctuation significantly affects the final look, feel, and quality of the product.

Importance of Mould Temperature Control

The precision of mould temperature control is a vital aspect of the injection moulding process. The goal is to maintain the mould surface temperature within a specific range to ensure optimal conditions for the plastic material to flow, fill the mould cavity, and solidify into the desired shape.

The mould temperature is typically controlled using cooling or heating channels within the mould. These channels carry a coolant, often water, that regulates the mould’s temperature by either removing or adding heat. The design of these channels, including their diameter, number, location, and distance from the mould’s surface, is crucial to the performance of the moulded part.

Mould Temperature and Material Behaviour

The mould temperature plays a significant role in determining the behaviour of the plastic during the injection moulding process. For instance, in amorphous polymers like Acrylonitrile Butadiene Styrene (ABS) and polycarbonate, higher mould temperatures result in lower levels of moulded-in stress. Consequently, the final product has better impact resistance, stress-crack resistance, and fatigue performance.

On the other hand, in semi-crystalline plastics, the mould temperature is a key factor in determining the degree of crystallinity in the polymer. The degree of crystallinity influences many performance parameters, including creep resistance, fatigue resistance, wear resistance, and dimensional stability at elevated temperatures.

Mould Temperature and Injection Pressure

The mould temperature also impacts the injection pressure required during the injection moulding process. The injection pressure is the force that propels the plastic to flow, and it varies depending on the mould temperature. A higher mould temperature reduces the viscosity of the molten plastic, making it easier to flow and fill the mould. Conversely, a lower mould temperature increases the plastic’s viscosity, requiring a higher injection pressure to fill the mould.

Mould Temperature and Injection Time

Another critical parameter influenced by mould temperature is the injection time, which refers to the time taken for the plastic melt to fill the cavity. The injection time must be carefully adjusted according to the mould temperature to ensure that the mould is completely filled before the plastic solidifies. This precision in setting the injection time is crucial for improving the surface quality of the products and reducing dimensional variance.

Importance of Mould Locking Pressure

To resist the injection pressure, it is necessary to use mould locking pressure. The objective is to calculate a suitable value considering the projected area. The projected area of injection moulded parts is the maximum area seen from the direction of the clamping force. The appropriate mould locking pressure helps to maintain the integrity of the mould and ensure that the moulded part accurately represents the design.

Back Pressure and Its Role

Back pressure refers to the pressure that must be produced and exceeded before the screw retreats. Although a high back pressure is beneficial for pigment dispersion and plastic melting, it prolongs the screw’s return time, reduces the length of the fibre in the filled plastic, and increases the stress on the injection moulding machine. Therefore, the back pressure should be as low as possible, generally not exceeding 20% of the injection pressure.

Mould Temperature and the Cooling Process

A significant phase of the injection moulding process influenced by mould temperature is the cooling process. The objective of the cooling process is to lower the temperature of the moulded plastic to the point where it solidifies. Once the plastic solidifies, it can be demoulded. The cooling process needs to be carefully controlled to minimise warpage, twisting, or other shrinkage-related problems.

Mould Temperature and Its Impact on Final Products

The mould temperature significantly affects the final properties of a moulded product. A product cooled too quickly could become brittle and crack under pressure or force. On the other hand, slow cooling could result in a part with lower stress resistance and a higher propensity for warping or distortion. Hence, the mould temperature should be carefully regulated to balance these factors and produce a high-quality moulded part.

Key Takeaways

In conclusion, mould temperature plays a pivotal role in the injection moulding process. It influences the behaviour and transformation of the material, the injection pressure and time, the cooling process, and the final properties of the moulded part. By carefully controlling the mould temperature, manufacturers can optimise the injection moulding process to produce high-quality, durable, and precise moulded parts. Therefore, understanding and managing mould temperature is a critical aspect of successful injection moulding production.

To find out more about the injection moulding process, mould temperature control and mould tool design please contact Benn Simms benn.simms@ledwellplastics.com Managing Director of Ledwell

Plastic product design | Innovative plastic product design for cost-effective manufacturing.

Posted on July 19, 2023August 26, 2023 by Peter Wilkinson

Innovative plastic product design for cost-effective manufacturing.

Plastics have become an integral part of our daily lives, being used in a wide range of products and applications, from packaging and consumer goods to automotive and aerospace components. As such, engineers are constantly looking to optimise the design of plastic products for both value and manufacturability. In this article, we will explore plastic product designs that have been engineered to achieve these goals, with a focus on the analytical processes and considerations that go into their creation.

Product design | Injection moulding plastics

Product design grill | Injection moulding plastics

Lightweight materials for transportation

Plastics have revolutionised the transportation industry by providing lightweight and durable materials that improve fuel efficiency and reduce emissions. Automotive manufacturers have turned to plastics for their exterior and interior components, including bumper facias, door panels, and instrument panels. Airplanes have also adopted plastic composites for structural components, such as wings and fuselage panels. Through careful design and analysis, engineers have been able to optimise these components for both value and manufacturability, all while reducing weight and improving performance.

Sustainable packaging solutions

As society becomes more environmentally conscious, plastics manufacturers have been tasked with developing sustainable packaging solutions that reduce waste and minimise the impact on the environment. This has led to a shift towards biodegradable and compostable plastics, as well as the use of recycled materials. Designers are also exploring new ways to reduce the amount of plastic used in packaging, such as innovative shapes and closures that require less material. These thoughtful designs prioritise both value and sustainability, creating products that not only meet consumer demands but also align with the company’s environmental goals.

Enhanced safety features

Plastics have revolutionised the safety features of many products, including those in the medical and automotive industries. In medical devices, plastics are used in life-saving equipment such as pacemakers, artificial joints, and prosthetics. In the automotive industry, plastics have made significant contributions to safety by reducing the weight of the car and improving crash performance. Through careful analysis and testing, engineers have developed designs that prioritise safety without sacrificing functionality or cost-effectiveness.

Improved aesthetic appeal

In addition to practical considerations, plastics designers are also focused on improving the aesthetic appeal of their products. This has led to the development of new textures, colours, and finishes that enhance the product’s visual appeal while maintaining its overall functionality and value. Creative designs and custom moulding techniques have allowed for endless possibilities in product design, resulting in products that are not only functional but also visually attractive.

Customisable products for individual needs

One of the many advantages of plastic products is their versatility and ability to be easily customised to meet individual needs. This is particularly evident in the medical industry, where prosthetic limbs and other medical devices can be customised to fit an individual’s body in a way that is not possible with traditional materials. The flexibility of plastics also allows for cost-effective small production runs customised to meet specific requirements, making them an attractive option for businesses with unique product needs. Overall, the flexibility of plastics enables designers to create products that meet the individual needs of consumers while maintaining the desired level of value and manufacturability.

Innovation in technology.

The plastic industry continues to push the boundaries of innovation in technology, with new materials and techniques constantly being developed. This includes the use of 3D printing, which allows for the creation of intricate designs and prototypes with ease, as well as the development of smart plastics that can sense and respond to changes in their environment. The use of nanotechnology is also being explored, offering the potential for plastics with enhanced properties such as increased strength and durability. By investing in research and development, the plastic industry is continually improving and expanding its capabilities, leading to a world filled with modern and innovative products.

Cost-effective solutions

Another benefit of plastic products is their cost-effectiveness, making them an attractive option for businesses and consumers alike. Compared to traditional materials such as metal or glass, plastic is much cheaper to produce, transport and dispose of. This is particularly evident in the fast-moving consumer goods industry, where packaging costs can be a significant part of the overall cost of the product. The use of plastic packaging allows for lower production costs, which are then passed on to the consumer in the form of lower prices. The affordability of plastics has played a significant role in their widespread adoption and success in modern society.

Conclusion:

In conclusion, the versatility, functionality and cost-effectiveness of plastic products have allowed for a plethora of innovation, and the industry continues to push the boundaries of what is possible. From enhancing safety and sustainability, to improving aesthetic appeal and meeting individual needs, plastics have revolutionised the way products are designed, manufactured and used. While there are valid concerns about plastic waste and its impact on the environment, the industry is taking steps to address these issues, such as increasing the use of recycled materials and exploring biodegradable options. As consumers, it is important to be mindful of our consumption habits and choose products that are sustainable and environmentally friendly. Overall, the plastic industry offers a world of possibilities, and with continued innovation and responsible use, it will remain an essential part of modern society.

For more information on plastics product design and how they are engineered for value please contact Benn Simms benn.simms@ledwellplastics.com Managing director of Ledwell.

Injection moulding quality | Control of material flow in a runner system to optimise injection moulding quality.

Posted on July 18, 2023August 26, 2023 by Peter Wilkinson

Injection moulding quality

Injection moulding quality and the optimisation of the runner system’s design.

Injection moulding is a widely used manufacturing process to produce high-quality plastic components with excellent dimensional accuracy and surface finish. However, the process is highly complex, and any deviation in the material flow can significantly affect the consistency and quality of the final product. Therefore, it is crucial to optimise the runner system’s design and control the material flow to ensure uniform filling and minimise defects. In this article, we will discuss the control of material flow in a runner system to optimise injection moulding quality. This guide is intended for engineers, product designers, mould designers, toolmakers, and mould makers seeking to improve their injection moulding processes and achieve consistent, high-quality results.

1. Importance of Runner System Design

The runner system is a crucial component in the injection moulding process and the injection moulding quality. A well-designed runner system can ensure consistent material flow and minimise defects. It is essential to consider factors such as gate types, gate locations, and runner size when designing the runner system. A small gate can lead to high injection pressure and poor part quality but does allow for a faster cycle time and the potential for self-trimming gates such as sub gates which reduce part cost. A large gate can increase cycle time and slow down production and will also need a separate trimming operation. Therefore, selecting the right gate type and location is critical for achieving optimal injection moulding quality.

2. The Role of Material Properties

Another essential factor that can affect material flow is the material properties. It is crucial to understand the viscosity and flow rate of the material being injected to optimise the runner system design. The material’s viscosity can impact the gate size, while a low flow rate can increase dwell time and affect the melt’s temperature. Therefore, it is essential to choose the right material and adjust the runner system design accordingly to achieve optimal injection moulding quality. The type of material is also a consideration a Crystaline or semi-crystalline material will behave very differently to an amorphous material, and this will often impact the gate and runner design and type chosen for the application.

3. Simulation Software

Simulation software can aid in designing a runner system by predicting the flow of the material within the mould. It allows designers to simulate various scenarios and optimise design parameters before creating the final mould. By simulating the injection moulding process, designers can predict potential issues such as weld lines, air traps, and flow hesitation. This approach helps in reducing the iterations required during the mould design process and optimising the runner system design for optimum injection moulding quality.

4. Sustainable Runner System Design

In recent years, there has been a growing interest in sustainable manufacturing practices and reducing waste in the injection moulding process. Runner systems can contribute to material waste, as they are often discarded after each cycle. One solution is to design a cold runner system, where the runners are not ejected with the part and can be re-processed and fed back into the machine to use in subsequent cycles. Another option is to create a hot runner system, where the runner material is kept melted and reused in the next cycle, reducing waste and energy consumption. Sustainable runner system design not only benefits the environment but can also lead to cost savings and increased efficiency.

5. Runner Balancing

Balancing the runner system is crucial for achieving consistent material flow and preventing defects in the final product. This stage is often overlooked by toolmakers and imbalanced runners can lead to variations in filling time and pressure, causing issues such as short shots, sink and warpage. Balancing the runner system involves adjusting the runner length, diameter, and placement to ensure equal pressure and material flow to each cavity. This process can be time-consuming but is essential for achieving optimal injection moulding quality.

6. Design for Manufacturability

Design for manufacturability (DFM) is a concept that involves designing parts and moulds that are optimised for the injection moulding process. By considering DFM principles, designers can ensure that the part is mouldable, with appropriate wall thickness, draft angles, and gating locations. These factors can impact the runner system design and ultimately affect the part’s quality. Designing for manufacturability can reduce lead times, decrease costs, and improve quality control in the injection moulding process.

In summary, controlling material flow in a runner system is crucial to achieving optimal injection moulding quality. A well-designed runner system, consideration of material properties, simulation software and using well-established practices to ensure the runner is designed properly, can significantly impact the final product’s consistency and quality. Optimising the injection moulding process requires a thorough understanding of the runner system and its role in the overall process. By following these guidelines, engineers, product designers, mould designers, toolmakers, and mould makers can improve their injection moulding processes and achieve consistent, high-quality results.

In conclusion, there are various factors to consider when designing a runner system for injection moulding. optimising the runner system design can result in consistent material flow, reduced defects, and improved product quality. Using simulation software and designing for sustainability and manufacturability can also improve the injection moulding process’s efficiency and reduce waste. Balancing of the runner system is also crucial for ensuring optimal quality and preventing downtime. By following these guidelines, manufacturers can achieve consistent, high-quality results in their injection moulding processes.

For more information about runner system design and injection moulding quality, please contact Benn Simms, benn.simms@ledwellplastics.com Managing Director of Ledwell

Injection Moulded | Ledwell are moving from strength to strength

Posted on June 29, 2023August 26, 2023 by Peter Wilkinson

Injection Moulded | Ledwell Plastics Newsletter

Injection Moulded is the monthly newsletter from Ledwell Plastics. Get ready to be inspired! We’re excited to introduce Ledwell’s monthly newsletter. Our goal is to give you an inside look at our company culture, introduce you to our team, and provide valuable insights into our business strategy.

Each month, we’ll feature a different member of our team and highlight their unique contributions to our company’s success. You’ll get to know us on a personal level and see how our team’s expertise and passion drive our business forward.

In addition, our newsletter will provide you with valuable industry insights, trends, and news. You’ll be the first to know about the latest developments in our field and how we’re staying ahead of the game.

Don’t miss out on this opportunity to connect with Ledwell and stay informed about our company’s progress. Sign up for our newsletter today and join our community of innovators and thought leaders. Ledwell.

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Paige Quality Control - injection moulding

Peter Wilkinson - Marketing Manager injection moulding

Injection mould design - Product Development

Let’s clear up the Great Moulding vs Molding Debate: Unraveling the Spelling Confusion in the Plastic Manufacturing Industry

The manufacturing industry is complex, with many different sectors and processes to keep track of. One area where confusion often arises is in the spelling of certain words, such as “moulding” and “molding.” Many people use these terms interchangeably, while others argue that one spelling is correct and the other is not. This confusion is especially prevalent in the plastic manufacturing industry, where these terms are used to describe the process of shaping plastic into various forms. In this blog post, we will attempt to unravel this mystery by exploring the history of these words, their meanings, and the arguments for and against each spelling. By the end of this post, you will have a clear understanding of the spelling differences between moulding and molding and be able to confidently use the correct term in your own industry.

1. Introduction: The ongoing debate over “moulding” vs “molding”

The world of plastic manufacturing is no stranger to debates and discussions. One such debate that has been ongoing for years is the spellings of the word “moulding” and “molding”. While it may seem like a trivial matter to some, those involved in the industry know that the choice of spelling can have a significant impact on how products are perceived and marketed.

In the United Kingdom and other Commonwealth countries, the term “moulding” is commonly used, following the traditional British English spelling. This spelling is derived from the Old English word “mold”, which refers to the hollowed-out form used to shape molten plastic. The use of the letter “u” in “moulding” is a reflection of the British English spelling conventions.

On the other side of the Atlantic, in the United States and other countries influenced by American English, the term “molding” prevails. This spelling aligns with the American English preference for simplified spellings, eliminating the letter “u” and adhering to a more phonetic representation of the word.

The debate over “moulding” versus “molding” goes beyond mere spelling preferences. It raises questions about regional differences, cultural influences, and even the potential impact on international trade and communication within the industry. Manufacturers and suppliers operating in both markets often find themselves navigating the nuances of language and spelling to effectively reach their target audiences.

In this blog post, we aim to unravel the confusion and shed light on the factors influencing the choice of “moulding” or “molding” within the plastic manufacturing industry. By exploring the historical, linguistic, and practical aspects of this debate, we hope to provide valuable insights for professionals and enthusiasts alike.

So, whether you find yourself using “moulding” or “molding” in your everyday conversations or written communications, join us as we delve into the intricacies of this spelling confusion and discover the fascinating world behind these seemingly simple words.

2. The historical context of the spelling variations

To truly understand the spelling variations and the ongoing debate between “moulding” and “molding” in the plastic manufacturing industry, it is important to delve into the historical context behind these two terms.

The word “moulding” traces its origins back to British English, where it has been used for centuries to refer to the process of shaping or forming materials into a desired shape or form. This term was commonly adopted in industries across the United Kingdom and its colonies, including Canada, Australia, and India.

On the other hand, the term “molding” emerged in American English during the early 19th century. It quickly gained popularity and became the standard spelling in the United States and other English-speaking countries influenced by American culture.

The spelling variation between “moulding” and “molding” can be attributed to both linguistic and cultural differences. British English tends to retain the original spellings of words derived from French, such as “moulding” derived from the French word “moule.” In contrast, American English has a tendency to simplify spellings and remove silent letters, hence the preference for “molding.”

The emergence of the internet and globalised communication has further complicated the spelling confusion. With the widespread use of digital platforms, companies from both sides of the Atlantic now interact and collaborate more frequently. This has led to mixed usage of “moulding” and “molding” in various contexts, causing confusion and debate within the industry.

While some argue that “moulding” should be the preferred spelling due to its historical precedence and global usage, others advocate for “molding” as the more commonly accepted form in modern English.

Ultimately, it is important for professionals in the plastic manufacturing industry to be aware of the historical context and spelling variations. This knowledge can help navigate discussions and ensure effective communication among stakeholders from different linguistic backgrounds.

3. Understanding the differences in British and American English

When it comes to the English language, there are often variations in spelling between different countries. The plastic manufacturing industry is no exception to this, with one particular word causing confusion and sparking a debate: moulding or molding?
The difference in spelling between “moulding” and “molding” can be attributed to the variations in British and American English. In British English, the word is typically spelled as “moulding,” while in American English, it is more commonly spelled as “molding.” This difference can be traced back to the historical development of the English language in each country.

It is important to note that while the spelling may differ, both “moulding” and “molding” refer to the same process in the plastic manufacturing industry. Whether it is the process of shaping molten plastic into a desired form or the final product itself, the term is used interchangeably to describe the process and its outcome.

For businesses operating in the plastic manufacturing industry, it is crucial to be aware of these spelling differences, especially when dealing with international clients or partners. Using the appropriate spelling based on the target audience can help maintain clear communication and avoid any confusion.

To navigate this spelling confusion, it is advisable to tailor your language usage based on your target market. If you primarily serve a British clientele, using “moulding” would be more appropriate. On the other hand, if your focus is on the American market, “molding” would be the preferred spelling.

Ultimately, understanding the differences in British and American English spelling is essential in the plastic manufacturing industry. By being aware of these variations and adapting your language accordingly, you can ensure effective communication and avoid any unnecessary confusion or debates surrounding the spelling of “moulding” or “molding.”

4. The impact of the plastic manufacturing industry on the spelling controversy

The plastic manufacturing industry has had a significant impact on the ongoing debate surrounding the spelling of “moulding” and “molding.” This controversy stems from the historical differences between British English and American English spellings.

In British English, the term “moulding” is commonly used to refer to the process of shaping plastic materials. This spelling aligns with the traditional British spelling conventions, where the letter “u” is added after the “o” in words like “colour” and “favour.” This spelling has been widely accepted and used in the plastic manufacturing industry in many parts of the world.

On the other hand, American English favors the simplified spelling of “molding” without the added “u.” This spelling adheres to the American preference for more streamlined and simplified spellings. As a result, the term “molding” has become widely adopted and used in the plastic manufacturing industry in the United States and other regions influenced by American English.

The impact of this spelling controversy extends beyond mere linguistic differences. It has practical implications for businesses operating in the plastic manufacturing industry, particularly those engaged in international trade. Companies must navigate the diverse spellings used in different regions to effectively communicate and promote their products.

This debate has also sparked discussions about standardisation within the industry. Some argue that adopting a single spelling, regardless of regional variations, would simplify communication and promote consistency. Others, however, believe that preserving the diverse spellings reflects the linguistic heritage and cultural nuances of different regions.

In conclusion, the plastic manufacturing industry has played a significant role in fueling the ongoing debate regarding the spelling of “moulding” versus “molding.” The clash between British English and American English conventions has led to a divergence in spellings used within the industry, highlighting the importance of clear communication and the need for consistent standards.

5. Regional preferences and industry standards

When it comes to the spelling of “moulding” versus “molding,” regional preferences and industry standards play a significant role. The variation in spelling can often cause confusion, especially in the plastic manufacturing industry.

In countries like the United Kingdom, Australia, and Canada, the preferred spelling is “moulding,” which is derived from British English. This spelling is also commonly used in other industries such as woodworking and construction. On the other hand, in the United States, the preferred spelling is “molding.”

These regional preferences can be attributed to historical linguistic differences and the influence of British colonisation. Over time, these spelling variations have become ingrained in the respective regions’ language conventions and are accepted as the standard.

However, it is crucial to note that industry standards may also impact the choice of spelling within the plastic manufacturing industry. Some organisations and companies may adhere to specific guidelines or standards that dictate the preferred spelling to ensure consistency and clarity within their documentation and communication.

Therefore, when navigating the moulding/molding debate in the plastic manufacturing industry, it is essential to consider both regional preferences and industry standards. Understanding these nuances can help avoid confusion and ensure effective communication within the industry, regardless of the chosen spelling.

6. The role of globalisation in resolving the spelling confusion

Globalisation has undoubtedly played a significant role in resolving the spelling confusion between “moulding” and “molding” in the plastic manufacturing industry. With the rapid expansion of business activities across borders, companies are increasingly engaging in international trade and collaboration. As a result, standardisation efforts have been made to ensure consistency in terminology, including spelling variations.

One of the key contributors to the resolution of this debate is the harmonisation of industry standards. Organisations and associations in the plastic manufacturing industry have recognised the importance of adopting a unified approach to terminology. Through collaborative efforts, they have developed standardised guidelines and terminology that encompass various aspects of the industry, including the spelling of commonly used terms like “moulding” or “molding.” This has helped eliminate confusion and promote a more streamlined approach to communication within the industry.

Furthermore, the emergence of digital platforms and the widespread use of the internet have accelerated the process of globalisation and facilitated the exchange of information. Professionals in the plastic manufacturing industry from different parts of the world can now connect and share knowledge more easily. This has allowed for discussions and debates surrounding the spelling confusion to take place on a global scale, ultimately contributing to a clearer understanding and consensus on the preferred spelling.

Additionally, multinational corporations and global supply chains have also played a role in shaping the spelling conventions in the industry. As these organisations operate in multiple countries and cater to diverse markets, they often face the need to standardise their communication and documentation practices. This includes adhering to a specific spelling preference for terms like “moulding” or “molding” to ensure consistency in their operations worldwide.

Overall, the process of globalisation has acted as a catalyst in resolving the spelling confusion between “moulding” and “molding” in the plastic manufacturing industry. Through standardisation efforts, increased connectivity, and the influence of multinational corporations, the industry has been able to establish a more unified approach to spelling, leading to clearer communication and reduced ambiguity.

7. How to choose the correct spelling for your plastic manufacturing business

Choosing the correct spelling for your plastic manufacturing business may seem like a trivial matter, but it can have a significant impact on your brand identity and how your target audience perceives your business. The spelling confusion between “moulding” and “molding” has been a long-standing debate in the industry, leaving many business owners unsure of which term to use.

One important factor to consider when making this decision is your target market. If your business primarily operates in regions that follow British English conventions, such as the United Kingdom or Australia, “moulding” would be the preferred spelling. This choice aligns with the linguistic norms of these areas and can help establish a sense of authenticity and familiarity with your local customer base.

On the other hand, if your business caters to the American market or operates in regions that predominantly use American English, such as the United States or Canada, “molding” would be the recommended spelling. This variant conforms to the language preferences of these areas and can enhance your brand’s credibility and resonance with American consumers.

Additionally, it is crucial to consider the industry standards and practices within your specific sector of plastic manufacturing. Research the prevailing spelling used by reputable companies in your industry and strive for consistency to avoid confusion among customers and stakeholders. Aligning your spelling choice with the industry norm can help establish your business as a knowledgeable and professional player in the market.

Ultimately, the decision between “moulding” and “molding” should be based on a combination of factors, including your target market, industry standards, and the image you want to project to your customers. By selecting the appropriate spelling, you can ensure that your brand messaging and communication are consistent, clear, and resonate effectively with your intended audience.

8. Tips for consistent and accurate spelling usage

When it comes to the spelling of “moulding” or “molding,” there is often confusion in the plastic manufacturing industry. Many wonder which spelling is correct, and whether it really matters at all. However, consistent and accurate spelling is crucial, as it reflects the professionalism and attention to detail of your business.

Here are some tips to ensure you use the correct spelling consistently:

1. Choose a standard: Decide on the preferred spelling for your industry or region. This can be influenced by factors such as customer expectations, industry norms, or regional language variations. Research what is commonly used and accepted in your specific context.

2. Consult industry resources: Refer to authoritative sources or industry style guides, such as technical manuals, trade associations, or professional publications. These resources often provide specific guidelines on preferred spellings for industry-specific terms.

3. Create an internal style guide: Develop an internal style guide that outlines the preferred spelling for terms related to plastic moulding/molding. This guide should be accessible to all employees and serve as a reference for consistent spelling usage across marketing materials, documents, and communications.

4. Train employees: Educate and train your employees on the correct spelling and its importance. Encourage them to double-check their written communications to ensure consistency and accuracy. This includes emails, reports, website content, and any other written material that represents your business.

5. Proofread and edit: Make it a habit to proofread and edit all written materials before finalising and publishing them. Look out for spelling errors and inconsistencies throughout the content. Consider using spell-check tools or seeking assistance from professional proofreaders to catch any overlooked mistakes.

6. Stay updated: Keep up with changes or updates in language conventions. Spelling usage can evolve over time, and it’s essential to adapt accordingly. Stay informed about any shifts in industry preferences or spelling conventions to maintain accuracy and relevance.

By following these tips, you can ensure consistent and accurate spelling usage in your plastic manufacturing business. This attention to detail will not only enhance your professionalism but also eliminate confusion and contribute to effective communication within the industry.

9. Addressing common misconceptions and myths

In the world of plastic manufacturing, there is a long-standing debate that has puzzled many: the spelling of “moulding” versus “molding.” This confusion has sparked numerous misconceptions and myths that often leave manufacturers scratching their heads.

One common misconception is that the choice between “moulding” and “molding” is simply a matter of regional preference. While it is true that the spelling can vary depending on the country or region, there are deeper factors at play.

The first myth we need to debunk is that “moulding” is the British spelling, while “molding” is the American spelling. While it is true that “moulding” is more commonly used in British English, it is not exclusive to this region. In fact, both spellings have been used interchangeably in various English-speaking countries.

Another misconception is that the spelling difference reflects a distinction in the manufacturing process. Some believe that “moulding” refers specifically to the process of shaping plastic using a mould, while “molding” refers to a broader range of manufacturing techniques. However, this is not accurate. The choice of spelling does not indicate any difference in the actual manufacturing process.

To further complicate matters, there are industry-specific terms that can contribute to the confusion. For example, in the construction industry, “molding” often refers to decorative trim or casing, while “moulding” is used to describe the process of creating these decorative elements. This usage can vary across different industries, adding to the complexity of the debate.

Ultimately, it is essential for manufacturers in the plastic industry to understand that the choice between “moulding” and “molding” is subjective. It depends on factors such as personal preference, regional conventions, and industry-specific terminology. What matters most is clear communication within the industry and a shared understanding of the intended meaning.

By addressing these common misconceptions and myths, we can untangle the spelling confusion surrounding “moulding” and “molding” in the plastic manufacturing industry. Let’s prioritise effective communication and focus on the quality of our products rather than getting caught up in a never-ending debate over spelling.

10. Conclusion: Embracing language diversity and clarity in the industry

In conclusion, the ongoing debate between “moulding” and “molding” in the plastic manufacturing industry can be seen as a testament to the diversity of language and the importance of clarity in communication.

While some may argue for the traditional spelling of “moulding,” emphasising its historical roots and adherence to British English, others may advocate for the simplified spelling of “molding,” which aligns with American English conventions and is increasingly accepted worldwide.

Rather than getting caught up in the spelling differences, it is crucial for professionals in the plastic manufacturing industry to prioritise clear and effective communication. This means ensuring that all stakeholders, regardless of their geographical location or preferred spelling, can understand and interpret the information accurately.

By embracing language diversity and accommodating different spellings, the industry can foster inclusivity and avoid any unintended misunderstandings. It is essential to establish clear guidelines and standards for terminology within the organisation to maintain consistency and prevent confusion.

Ultimately, the focus should be on the quality of the products and services provided by the plastic manufacturing industry rather than the spelling nuances. By prioritising effective communication and embracing language diversity, professionals in the industry can navigate the “moulding vs molding” debate with ease while focusing on delivering excellent results to their customers.

We hope this blog post has shed some light on the great moulding vs molding debate in the plastic manufacturing industry. While the spelling may differ depending on geographic location, it’s important to remember that both terms refer to the same process. Understanding this distinction can help prevent any confusion or miscommunication within the industry. Whether you’re a manufacturer, designer, or simply interested in the plastic manufacturing industry, we hope this article has provided you with valuable insights. Stay tuned for more informative content, and remember, no matter how you spell it, the world of plastic moulding/molding continues to shape our modern world.

Injection moulding services company Ledwell goes for growth

Posted on June 26, 2023August 26, 2023 by Peter Wilkinson

Injection moulding services company Ledwell purchases new factory to enable growth

As Ledwell’s business continues to grow, we are excited to announce that we have acquired a new factory site to better serve you. This expansion will help us to meet the increasing demand for our injection moulding services and allow us to provide even better quality and faster turnaround times. Our new factory site will allow us to increase our production capacity and improve our efficiency. We are proud to be able to continue to innovate and expand, and we look forward to the new opportunities this will bring for our customers.

Our goal has always been to provide high-quality products and services to our customers, and with the new factory site, we can now do so even more efficiently and effectively. This expansion will allow us to streamline our operations, which will ultimately benefit our customers. We are thrilled to embark on this new journey and look forward to the exciting opportunities that lie ahead.

Our previous site was operating at maximum capacity and we were finding it increasingly difficult to keep up with demand. Commenting on the new site, Benn Simms, Managing Director of Ledwell said “We found ourselves a victim of our own success. Our business grew substantially despite the challenging economic climate. It was soon realised that space was paramount to the continued success of Ledwell Plastics. After evaluating several properties near to our existing factories a suitable facility was found. We now have an efficient storage facility that is meeting our current needs and gives us capacity in line with our goals and strategy. I’m incredibly proud of our team and their achievements to adapt and continue to build on our 55 years”.

To find out more about Ledwell’s injection moulding services please contact Benn Simms benn.simms@ledwellplastics.com Managing Director of Ledwell.

Plastic Moulding Company Ledwell invests in In-Touch | Cutting-Edge IT Production Systems

Posted on June 26, 2023August 29, 2023 by Peter Wilkinson

Plastic Moulding Company Ledwell invests in In-Touch

Plastic moulding company Ledwell has been a leader in the plastic injection moulding industry for many years. To maintain our quality and drive our production efficiencies we have recently introduced, In-Touch, a new IT production system that has taken our production efficiency to the next level.

These new systems allow us to monitor all our machines in real-time, which gives us a better understanding of how operations are running. By monitoring our machines in this way, we can identify areas where improvements can be made. This has ultimately led to greater efficiency and increased productivity.

In today’s dynamic business environment, the ability to monitor and optimise production processes in real-time is crucial for manufacturers. With the increasing demand for higher-quality products and shorter lead times, companies need to adopt effective monitoring solutions that can help them identify potential problems early on and reduce downtime.

Intouch Monitoring is a cutting-edge software tool that provides real-time production monitoring for engineers, product designers, and engineering designers. Since investing in this powerful tool Ledwell has realised greater efficiency and improved product quality.

Improved Efficiency:

Intouch Monitoring provides us with real-time data on production processes, which helps us identify where the bottlenecks are and where improvements could be made. By having access to this information in real-time, Ledwell’s team can make adjustments as needed, and streamline production. This reduces the amount of waste produced, minimising downtime and increasing overall production efficiency.

Enhanced Collaboration:

Intouch Monitoring helps us identify issues quickly, leading to faster solutions and reduced downtime. By pooling resources and knowledge, our teams can work together more effectively and make better decisions that improve product quality and overall production efficiency.

Job Planning

The use of Intouch’s unique built-in planning software allows for greater flexibility and adaptability. Machine setters have full access to the current plan in real-time rather than having to wait for a message and revised documentation.

Real-time quality data

Having access to real-time scrap data is essential for consistent product delivery, to our customers. This enables us to understand any potential issues with moulding or tooling and rectify them early on before they become costly and detrimental to the delivery schedule. Our operators log the scrap as it happens, so we have the data immediately at our fingertips.

To find out more about the advantages of In-Touch and how it will improve production lead times and quality please contact Benn Simms benn.simms@ledwellplastics.com Managing Director of plastic moulding company Ledwell

Ledwell | Plastic Moulders Make Major Investment in Injection Moulding Machines & Robots

Posted on June 20, 2023August 25, 2023 by Peter Wilkinson

Ledwell | Plastic Moulders Make Major Investment in Injection Moulding Machines & Robots

To maintain our growth, offer clients more scope and improve production efficiencies plastic moulders are investing in new injection moulding machines and robots.

Benn Simms, Managing Director of Ledwell said, “We are a leading injection moulding company in the UK. To maintain our position and offer clients the solutions they need, we are continually investing in new technologies”.

How Plastic Moulders are Improving Production Efficiency in Injection Moulding with Robotic Automation

In today’s fast-paced injection moulding industry, companies are constantly seeking ways to improve production efficiency and gain a competitive edge. With the advent of robotic automation, injection moulding companies can now streamline their operations, enhance product quality, and increase overall productivity. In this article, we will explore the various ways in which robots can and have improved the production efficiency of injection moulding, at Ledwell, along with the benefits they bring to the table.

The Rise of Robotics in Injection Moulding

The demand for more flexible solutions in the plastics industry has led to the extensive use of industrial robots in injection moulding operations. These robots can automate the entire injection moulding process, from loading plastic parts into the machine to placing the finished products onto a conveyor belt. By replacing human-operated injection moulding with robots, companies can ensure the consistent production of high-quality products that are accurately formed.

Advantages of Robotic Automation

The utilisation of robotics in injection moulding offers several advantages for manufacturers. Firstly, it provides them with a competitive advantage by increasing both productivity and the quality of the produced parts. Robots can work faster and more efficiently than humans, leading to higher output and reduced cycle times. Additionally, robots can perform highly repetitive tasks 24/7 without the need for breaks or rest, maximising the utilisation of injection moulding equipment and increasing overall efficiency.

Another significant advantage of robotic automation is the improvement in product quality. Robots can perform precise and repeatable tasks, ensuring consistent quality and reducing the risk of errors or defects. They can also handle parts in a controlled and consistent manner, reducing the risk of contamination and improving the overall quality of the final product. By incorporating robots into the injection moulding process, manufacturers can reduce waste, minimise the need for rework or scrap, and deliver products that meet the required specifications.

Application of Robotics in Injection Moulding

Robots have a wide range of applications in different stages of the injection moulding process. One common application is machine tending, where robots are used to unload finished parts from the injection moulding machine and deliver them to downstream processes such as packaging. By automating this task, manufacturers can improve product consistency, reduce the risk of injuries to labourers, and increase production capacity.

Another important application is insert moulding, which involves enclosing inserts such as pins or threaded rods in moulded plastic. Robots, such as SCARA robots, can add inserts to mouldings and load them into machines to continue the process. They can also work in collaboration with pick-and-place robots to complete the manufacturing process.

Automation can also be applied to over-moulding, where a moulded object is removed from one injection moulding machine and placed into another with the help of a robot. This automated process ensures a more efficient and accurate arrangement of parts, reducing labour and assembly expenses while ensuring the quality and integrity of the final product.

In-mould labelling is another popular application for automation in injection moulding. Robots can feed pre-printed labels or decorated film directly into the open plastic injection mould, ensuring precise and stable positioning of labels. This process enhances the visual appeal of the final product and eliminates the need for secondary processing or shipping parts to and from warehouses.

Post-processing tasks, such as inspection, testing, and trimming of plastic moulded parts, can also be automated using robots. Robotic trimming cells provide superior repeatability compared to manual trimming, resulting in higher precision, accuracy, and cycle times. Robots can minimise waste and improve production efficiency by reducing errors and defects.

The Future of Robotic Technology in Injection Moulding

The future of robotic technology in injection moulding looks promising, with ongoing advancements aimed at simplifying operations and maximising overall equipment effectiveness. Companies like Sepro Group are breaking new ground in the area of robot and automation control. Their work focuses on simplifying robot programming with the use of artificial intelligence (AI) and creating highly integrated control systems that communicate with all equipment in a production cell.

Plastic moulders can overcome the technical complexities associated with robot programming by implementing “no-code” programming and AI-driven robot controllers. This enables easier retrofitting of code or hardware to evolving business and market needs, making robotic automation more accessible and user-friendly. As a result, even relatively new employees with limited training can set up basic moulding processes, further reducing the need for skilled technicians.

In conclusion, robotic automation offers immense potential for improving production efficiency in injection moulding. Manufacturers can increase productivity, enhance product quality, and reduce costs by utilising robots in various stages of the process. Robots’ flexibility, precision, and efficiency contribute to the overall competitiveness of injection moulding companies. As technology advances, the future of robotic automation in injection moulding looks promising, paving the way for further innovations and improvements in the industry.

Plastic Injection Mould Design Modelling Software | Peace of mind that your designs are refined, reliable and ready to be produced

Posted on June 8, 2023August 29, 2023 by Peter Wilkinson

Plastic Injection Mould Design Modelling Software | Ledwell Uses State of the Art Flow Modelling and Simulation Software

Commenting on plastic injection mould design modelling and moulding simulation software, Benn Simms, Managing Director of Ledwell said, “The importance of injection moulding simulation in mould tool design cannot be overstated. Here at Ledwell we use state of the art software to help us design our mould tools.” Benn went on, “that said, there is no replacement for the knowledge and skills that our engineers have. The mould tool design software enhances those skills”.

Benn explained: Creating high-quality injection moulded parts is crucial for our client’s successful production. To achieve this, we rely on advanced design modelling software that allows us to analyse and optimise the design and flow of their injection moulded parts. This technology, known as injection moulding flow simulation, has revolutionised our Industry. It provides our designers and engineers with valuable insights and data early in the development cycle.

Let me explain a bit more:

What is Injection Moulding Simulation?

Injection moulding simulation involves the use of sophisticated software programs to create virtual simulations of the injection moulding process. By inputting the CAD model of the part or mould tool, the software generates a finite element mesh that accurately represents the part. This mesh serves as the basis for analysing the complete injection moulding process, predicting and visualising what happens at each stage of the cycle.

Benefits of Injection Moulding Simulation

Optimised Filling and Packing Phase: One of the key benefits of injection moulding simulation is its ability to optimise the filling and packing phase of the process. By analysing the filling characteristics, such as filling patterns, pressure requirements, temperature maps, and air-traps, the simulation helps determine the optimum number and position of gates. This insight allows our designers to make informed decisions that result in better-quality parts.

Reduced Time and Cost: By using injection moulding simulation, our production engineers can minimise the number of physical tool trials required. This not only shortens the time-to-market but also reduces the overall cycle time and scrap rate. Additionally, the simulation helps identify potential issues, such as surface defects, weld lines, and sink marks, early in the design phase, saving time and resources that would otherwise be spent on tool modifications.

Improved Cooling System Efficiency: The cooling phase of the injection moulding process accounts for a significant portion of the total cycle time. Injection moulding simulation allows for the analysis of the mould’s cooling system function and efficiency. By optimising the cooling circuit parameters, such as the use of high-conductivity metal inserts or baffles, our designers can maximise heat-removal efficiency and produce high-quality parts in the shortest time possible.

Warpage Analysis and Solution: Injection moulding simulation is also invaluable in identifying and addressing part distortion or warpage issues. By analysing variations in shrinkage driven by factors such as volumetric shrinkage, pressure, crystallinity, stress relaxation and orientation our designers can make design modifications or adjust process parameters to achieve stable and optimal solutions.

Benn concludes: There are several design modelling software options available that specialise in injection moulding simulation. These software programs provide a range of features and capabilities to streamline the design for manufacturing (DFM) process and enhance the overall productivity and efficiency of injection moulding operations.

Injection moulding simulation has become an essential tool for injection moulders, generally, in the design and production of high-quality injection moulded parts. By using our advanced design modelling software, Ledwell gains valuable insights into the injection moulding process, optimises design and process parameters, and reduces time and cost associated with physical tool trials. With the ability to simulate and analyse the filling, packing, and cooling phases we can produce higher-quality parts and improve productivity.

To find out more about Ledwell’s injection moulding simulation, contact Benn Simms benn.simms@ledwellplastics.com Managing Director of Ledwell.

Plastic Moulded Products | Ledwell Implements New dedicated assembly lines to support our clients’ requirements.

Posted on June 8, 2023August 29, 2023 by Peter Wilkinson

Streamlining Production of Plastic Moulded Products: How Dedicated Assembly Lines Benefit Ledwell and Our Clients

Ledwell has invested in new dedicated assembly lines to give our clients the solutions they need.

Commenting on the new assembly lines at Ledwell, Matt Aucott, Production Director of Ledwell said, “In today’s fast-paced business world, it’s crucial to find ways to increase efficiency and reduce costs of plastic moulded products. One of the most effective ways to achieve these goals is through the use of dedicated assembly lines. Ledwell’s production lines are designed to streamline the assembly of plastic moulded products and post-moulding production processes by breaking tasks down into smaller, more manageable steps. By doing so, they minimise the amount of time workers spend moving parts and materials around, and maximise the time spent actually assembling products”.

Matt explained further. “Ledwell’s assembly lines divide the production process into smaller, simpler steps, and assign each step to a specific worker or machine. The plastic moulded products moves along a conveyor belt or other system, with each step of the process performed at a different station along the line.

By streamlining the production process into smaller, simpler steps, workers can become experts in their specific area, leading to increased efficiency and higher-quality products. Additionally, assembly lines can be designed to maximise the use of space and materials, reducing waste and lowering costs. They can also be easily scaled up or down to meet our changing production demands”.

Matt went on, “One key aspect of assembly lines is the use of automation and machinery to perform repetitive tasks. This not only speeds up production, but also reduces the risk of human error. However, it’s important to note that assembly lines still require skilled workers to oversee the process, troubleshoot any issues and perform more complex tasks that can’t be automated.

By implementing dedicated assembly lines in our production process, we have brought numerous benefits to our business. First and foremost, we have significantly increased our production efficiency. By having dedicated assembly lines, each worker can focus on a particular task which they become highly skilled at performing. This results in faster production times and fewer errors or defects, leading to an overall increase in productivity and quality of output”.

Other benefits we have identified include:

improved safety
better inventory and supply chain management
reduced lead times and faster turnaround

Commenting on the benefits to Ledwell, Matt said, “One of the greatest benefits of implementing dedicated assembly lines was reduced lead times and faster turnaround. With each assembly line dedicated to a specific set of tasks, the production process becomes more streamlined and efficient. This enables us to produce more products in less time, resulting in a quicker turnaround time for our customers”.

“Dedicated assembly lines have been a game-changer for Ledwell”, Matt concluded.

To find out more about Ledwell’s dedicated assembly lines and how they may help your production requirements, please contact Matt Aucott matthew.aucott@ledwellplastics.com , Production Director of Ledwell.

Plastic Injection Moulding Near Me : Tips on Maintaining the Quality of High Gloss Injection Moulded Parts.

Posted on June 8, 2023August 26, 2023 by Peter Wilkinson

Plastic Injection Moulding Near Me: Tips for maintaining a high gloss finish. There is an art to keeping your high gloss in top condition

Plastic Injection Moulding Near Me | High gloss injection moulded parts are becoming increasingly popular for their sleek and modern look. However, maintaining the quality and shine of these parts can be a daunting task. Scratches, dust, and other damage can quickly diminish their appearance. In this article, we will provide you with tips and tricks on how to maintain the quality of these parts so that they stay looking as good as new for years to come. From cleaning and polishing techniques to proper storage and handling, you’ll learn everything you need to know to keep them looking their best.

1.0 What are high gloss injection moulded parts?

High gloss injection moulded parts are a popular choice for manufacturing a variety of products today. These parts are made by injecting molten plastic into a mould and then allowing it to cool and solidify into a specific shape and size. The result is a product that has a smooth, glossy finish that is both durable and aesthetically pleasing to the eye. These parts are used in everything from automotive interiors to consumer electronics to medical devices. They are particularly popular in industries where appearance and durability are crucial, such as the automotive and home appliance industries. High gloss parts are known for their excellent quality and have become widely used for manufacturing products that require a strong and attractive finish.

2.0 How to clean and polish high gloss injection moulded parts

High gloss parts and products are chosen by designers as they add a sleek and polished look. However, maintaining the quality of these parts requires a little extra effort and care. When it comes to cleaning and polishing these parts, there are a few things to keep in mind. First, you should always use mild soap and lukewarm water to clean the surface. Avoid using harsh chemicals or scrubbing brushes as they can scratch or damage the surface. Once you have thoroughly cleaned the surface, it’s time to polish it. There are several ways to polish the parts, but one of the most effective methods is to use a high-quality polish that is specifically designed for plastic surfaces. Apply the polish to a soft cloth and gently buff the surface in a circular motion. This will help to remove any minor scratches or blemishes and leave the surface looking shiny and new. It is important to remember that regular maintenance is key to keeping them looking their best. With a little extra care and attention, you can ensure that your products always shine on.

3.0 Proper storage and handling of high gloss injection moulded parts

Proper storage and handling of high gloss parts and products is essential to maintain their quality. It’s crucial to ensure that these parts are stored in a clean, dry, and dust-free environment. Any dirt or dust particles can scratch the surface of the parts, which can mar their high gloss finish. You should also avoid touching the high gloss surface directly with any sharp or abrasive objects as this can cause scratches or damage to the finish. When it comes to storing, you should use protective packaging or covers to avoid any contact with other objects that may scratch or damage the surface. If the parts are large and require stacking, you should use protective materials such as foam to prevent any damage from the pressure of the parts’ weight. It’s also important to store high gloss parts away from heat sources or direct sunlight. The heat can cause the parts to warp, and the sunlight can cause fading or discolouration over time. By following these proper storage and handling procedures, you can help maintain the quality and high gloss finish of your injection moulded parts, ensuring they look and perform their best for years to come.

4.0 Conclusion.

Maintaining the quality of your parts and products requires consistent effort and attention to detail. However, it is well worth the investment, as these parts can add a beautiful and polished look to any product. By using the right cleaning tools and techniques, avoiding harsh chemicals, and protecting the parts from scratches and damage, you can keep your products and parts looking like new for years to come. Whether you are a manufacturer or a consumer, these tips can help you get the most out of your parts and products. With a little bit of care and attention, you can keep your parts looking shiny and new for a long time.

For more information on the storage and upkeep of your high gloss injection moulded component and products, please contact Benn Simms, benn.simms@ledwellplastics.com Managing Director of Ledwell – Plastic Injection Moulding Near Me

Injection Moulded Parts | Advantages and Disadvantages

Posted on May 5, 2023August 29, 2023 by Peter Wilkinson

Injection Moulded Parts | Advantages and Disadvantages

Injection Moulded Parts | As engineers, we know that choosing the best manufacturing process for a particular product is crucial for its success in the market. Injection moulding is a widely used manufacturing process for producing plastic parts due to its high efficiency, repeatability, and ability to produce complex shapes. However, like any manufacturing process, it has its advantages and disadvantages that need to be carefully considered before implementation. In this article, we will analyse the advantages and disadvantages of injection moulding, providing a comprehensive understanding of this process for engineers seeking to make informed decisions for their projects.

Advantages of Injection Moulded Parts:

1.0 High Efficiency:

One of the biggest advantages of injection moulding is its high efficiency in producing plastic parts. The process involves feeding raw plastic material into a heated barrel, which is then melted and injected into a moulding cavity. The entire process takes just a few seconds, during which time multiple parts are moulded. With good mould tool design and under the right circumstances different parts can be produced simultaneously. As a result, injection moulding is highly efficient and reduces the cost per part.

2.0 Repeatability:

Another advantage of injection moulding is its ability to produce identical parts with high repeatability. This is due to the computer-controlled IM machinery, giving a consistent and repeatable process. This results in consistently shaped parts. As a result, the parts produced through injection moulding can be easily assembled with high levels of interchangeability, in various applications.

3.0 Production of complex shapes:

Injection moulding enables the creation of complex and intricate shapes that may be challenging to produce through other manufacturing techniques. The ability to produce parts with such complex geometries opens up exciting opportunities in various industries, including automotive, medical, and consumer electronics.

Disadvantages of Injection Moulded Parts:

1.0 Start-up Costs:

The biggest disadvantage of injection moulding is the start-up costs associated with the machinery, moulds, and equipment required. The cost of creating the moulding tools and setting up the initial process can be high, making it challenging for manufacturers looking for low-volume production runs. There are options to help with tooling cost reduction including the “Ledwell Plastics Rapid Tooling System”. However, due to the nature and requirements of the process, this cost does still need to be overcome.

2.0 Limited Material Compatibility:

An additional disadvantage of injection moulding is that it is limited to material compatibility. Certain materials cannot be easily processed through injection moulding. The design of components and parts needs to be considered carefully to make sure it is possible to produce them in the desired polymer. The choice of the wrong materials for components and parts that work together within an assembly may result in certain parts not functioning as they should. Careful consideration of the materials used needs to be addressed at the design and prototype stage to ensure cross-compatibility and correct product operation. Temperature is a part of this too. Although there are polymers that can withstand high temperatures they can often limit the design of the part due to the difficulty in processing them. Manufacturers must carefully consider the material selection before opting to use injection moulding.

3.0 Design Limitations:

Finally, injection moulding has design limitations that need to be considered when developing components. Often with thought and by working with an injection moulding company workarounds or design tweaks can overcome these limitations. Simply put the injection moulded parts must be designed with the moulding process in mind, and this can limit what designers can achieve creatively. Additionally, parts produced by injection moulding may require additional post-production processing, which may increase the overall cost.

Conclusion:

Injection moulding has many advantages, but these need to be weighed against the associated costs and limitations. Engineers must carefully consider their design requirements and materials, but working with an injection moulding company with sound knowledge of the process and limitations can often resolve such issues. By fully understanding the advantages and disadvantages of injection moulding, engineers can make informed decisions for their projects, both in terms of design and cost-efficiency.

To find out more about the advantages and disadvantages of injection moulding your products please contact Benn Simms benn.simms@ledwellplastics.com Managing Director of Ledwell

Ledwell Expands Quality Control | Meet Paige

Posted on May 5, 2023August 26, 2023 by Peter Wilkinson

Quality Control in the Field of Injection Moulding: An In-Depth Guide

Paige Otter- quality control Injection moulding

**Paige Otter, Ledwell’s Quality Control Supervisor

Injection moulding, a cornerstone manufacturing process, has been the backbone of the plastic industry for decades. It’s a complex procedure that requires precision, expertise, and strict quality control measures. This post delves into the quality control aspect of injection moulding, highlighting its importance, the procedures involved, and the benefits it offers.

The Art of Injection Moulding

Before diving into quality control, let’s understand the process of injection moulding. It’s a technique where molten plastic or composites are forced into a mould to create a part, a product or component. There is a wide range of different plastics to choose from as well as composites and biodegradable materials. The process begins with the material being heated until it becomes molten. It’s then injected into a mould under pressure, cooled to solidify, and eventually removed from the mould. The result is a solid part fashioned and engineered from your chosen material.

Injection moulding technology came into existence in the early 1870s, initially used to manufacture billiard balls. Fast forward to today, and injection moulding has become a versatile method to create a plethora of products – from drink tumblers and automotive parts to musical instruments and medical devices.

The Vital Role of Quality Control in Injection Moulding

In the world of injection moulding, quality control is crucial. It’s a systematic process that ensures the final products meet the set specifications and consumer expectations. Several factors, including dimensional stability, colour, gloss, and moulding defects, define how well the product aligns with the intended design and overall quality.

Quality control is not just a term used to boost brand image or a buzzword thrown around casually. It’s a rigorous process that involves meticulous planning, design, development, assembly, production, and packaging. Quality control measures are integral to the success of a business, reducing production costs and boosting customer satisfaction.

Dimensional Stability and Quality

Dimensional stability is an important aspect of quality control. If the product is an individual piece that doesn’t connect to anything, the dimensions might not matter. However, for components that fit together to form an assembled product, having the correct dimensions is crucial.

Each component must conform to specific dimensions to fit with other parts correctly. This includes being neither too large nor too small and maintaining the right shape to fit, perfectly with other components. If the components don’t fit together, the entire assembly might not function as intended, resulting in halted manufacturing lines or dissatisfied customers.

The Impact of Colour in Injection Moulding Quality Control

Colour is another critical factor that can affect the overall quality of the product. Changing process parameters, such as increasing or decreasing temperature and pressure, can affect the end colour of the product. There are different ways to colour the plastic, including pre-coloured plastic from a plastics manufacturer or a blended plastic created at the moulding factory.

Colour harmony is crucial to ensure each component meets the specification, meaning each part aligns with the intended colour within a few shades. It’s important to show uniformity and consistency of colour between all components, meeting the design intent.

The Role of Gloss in Product Quality

Gloss, though a small detail, can significantly influence the perceived quality of the product. The right gloss level can enhance your product’s visual appeal, influencing your consumer’s perception. The process parameters during moulding can influence gloss to a certain degree. For instance, high temperature may increase gloss, while the time in the mould could decrease the gloss level of your product.

Common Moulding Defects and Quality Control

Moulding defects can affect the quality of your product. The five most common defects that may occur include flow/weld lines, sink marks, short shots, burn marks, and flashing. Each of these defects can compromise the overall quality of the product, deterring customers from purchasing it.

However, not all defects warrant discarding the product. For instance, some defects might be acceptable on an internal component that isn’t visible after assembly. The product specification should outline if a defect is acceptable, its acceptable location, and the degree of defectiveness allowed.

Benefits of Quality Control in Injection Moulding

Quality control in injection moulding comes with numerous benefits. It encourages a quality-conscious approach among the workers, leading to higher product quality. It also reduces production costs by minimising waste and inefficiencies. Companies can ensure the utilisation of resources, improve employee morale, and satisfy customers by maintaining stringent quality control measures. Additionally, quality control helps identify and fix problems early, reducing returns and failures.

Quality Control Trends: AI and Advanced Quality Assurance Tools

Quality control in injection moulding has seen significant advancements with the emergence of artificial intelligence (AI) and advanced quality assurance tools. AI enables complex and reliable quality control systems, ensuring consistency in mass production. The integration of AI with quality control systems allows automatic adjustments to the moulding cycle, improving the overall production process.

In addition to AI, advanced quality assurance tools like IdentiPol QA2 have revolutionised quality control in injection moulding. It enables efficient quality assurance tests, ensuring consistency and quality across the production line. It’s a user-friendly tool that grades plastics based on a pass or fail basis, bridging the gap between simple testing and complex lab analysis.

To find out more about Ledwell’s quality control procedures please contact Paige Otter paige.otter@ledwellplastics.com Ledwell’s quality control supervisor.

Ledwell Plastics excels at injection mould design, toolmaking, plastics injection moulding, assembly, and just in time production. We offer a turnkey solution that can organise a new product launch from concept to consumer. We have a complete turn-key solution to bring your product to market, and we are ISO9001:2015 certified

Peter Has Taken on Technical Sales and Marketing at Ledwell

Posted on May 5, 2023August 25, 2023 by Peter Wilkinson

New Technical Sales and Marketing Manager at Ledwell

Ledwell Plastics are delighted to announce that Peter Wilkinson has joined the team as Sales and Marketing Manager.

Marketing Manager at Ledwell | Peter brings with him a great depth and breadth of experience, built on over 40 years of marketing technical and engineering products. His knowledge across the board will benefit our team at this exciting time of growth. Peter is here to help Ledwell’s clients with technical sales enquiries. From a mould making, casting and injection moulding background, Peter will ensure the best solutions are presented for your needs.

Benn Simms, Managing Director, commented; “I am looking forward to working with Peter and I am confident that the broad experience that he brings to the role will help to accelerate Ledwell to the next stage of our growth, whilst ensuring that we further develop strong systems and customer satisfaction levels”.

Peter added; “I’m delighted to join Ledwell at this exciting time of development across the business. I’m looking forward to a bright future with the company and working collaboratively with all our teams internally.”

To contact Peter for technical or sales enquiries please email peter.wilkinson@ledwellplastics.com or call Peter on 07930330125