What is the Cheapest Type of Plastic Molding?
Plastic injection molding is a very versatile manufacturing process that allows you to manufacture simple or complex designs in large quantities with short lead times. Injection-molded items and additives are discovered in almost every industry, way to layout flexibility, the velocity at which excessive portions may be produced, and the variety of substances from which to choose. This manufacturing method can make medical equipment for hospitals, defense, security, and industrial applications. Another big advantage of plastic injection molding is the price. This is often the most cost-effective method for manufacturing parts, especially in mass production. However, there are still many costs to consider when using injection molding for your project.
Injection molding is thought to be one of the cheapest plastic moldings compared to other types. but the basic difference of the cost is made with many different factors. Injection molding can also be made expensive if not supervised and kept under budget. As the product is produced, the cost of injection molding seems to increase rapidly. It’s only natural to feel a bit of a “sticker shock” when these products come out, especially if you’re cautious during the prototyping stage and rely on rapid prototyping and 3D printing to control costs.
From tooling manufacturing to machine setup and production time, the remaining stages of bringing your product to market are likely to represent a substantial portion of your overall investment. There are two main areas where you can reduce costs. The cost of capital (such as making molds) and the cost of the unit (detailed below).
1. Design Efficiency:
In this case, we will talk about production efficiency. It makes parts production, packaging, and finishing as easy as possible while minimizing errors. This means following plastic part design best practices such as adding the appropriate draft (or angle taper) to your parts for easier ejection, rounding out corners, keeping walls thick enough, and how the molding process generally works. is, designing your product to take advantage of it. With the efficient design, your overall cycle time will be shorter, reducing the machine time you pay for, and the number of parts you discard due to a production or ejection error, wasting your time and materials.
2. Runner System:
If your injection mold uses a hot runner system, the up-front tooling cost of the hot runner will increase, but the cost per piece will be lower. This is because there is less material waste since there is no runner system that needs scraping like a cold runner system. A cold runner system is a less intricate device but will cost more.
3. Usage of Core Cavities:
Designing hen hollow boxes or cylinder-shaped pieces, mold design, and configuration can make a big difference in the efficiency and cost of both mold production and your part production process. For those kinds of hollow shapes, the “core cavity” design provides a smart solution. The “core cavity” means that, instead of forming a half mold with deep, narrow walls to form the hollow part, the tool is machined around the shape of the cavity. It is a much less complex design with less margin for error, and material flow will be significantly easier during the production process.
4. Addition of Processes:
Unless required, textured, or otherwise customized part finishes should not be designed in a mold, other finishing processes should also be avoided unless they are integral to the function and purpose of your product.
5. Suitable Material:
Unless you are preparing a part for use in harsh environments such as extreme hot or cold, or for special grade uses such as medicine or food, the choice of material is often interchangeable. And choosing a low-cost material that still fits your needs is an easy and effective way to reduce your overall cost. A simple analysis of the use cases for your product, along with the quality requirements and your target market, can help you choose the right materials for your price point.
6. Structural Requirements Analyzation:
Before going into production, it can pay dividends to produce a plastics prototype to closely analyze the composition of your part to determine which areas are most important to its function and quality. When you look deeper into it, you can find areas where a gusset or rib provides the strength you need instead of a completely solid area. These types of design modifications, taken as a whole, can improve the structural integrity of your part, making it easier to produce.
7. Maximization of tool usage:
Here, we’re talking about reducing your per-part cost, which can help you amortize your mold costs to a greater extent while reducing your overall investment by creating efficiency in the production process. For example, when you can make a mold with six shots instead of just two shots, you increase your production speed faster, create less wear and tear on your mold, and market more quickly.