Injection Moulded Parts | Advantages and Disadvantages
May 5, 2023
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
