Injection Molding
Precision Manufacturing for High-Volume Production
AWAL injection moulding is a versatile manufacturing process that enables the efficient production of parts in large volumes. Whether you’re creating thousands of identical items or custom components, injection moulding offers speed, accuracy, and consistency
How Does Injection Moulding Work?
Mould Creation:
- The process begins with designing and creating the mould itself.
- Most moulds are crafted from metal, such as aluminium or steel, and precisely machined to match the desired product features.
Material Injection:
- The material—usually thermoplastic or thermosetting polymers—is fed into a heated barrel.
- A helical-shaped screw mixes and melts the material.
- The molten material is injected into the mould cavity, where it cools and hardens, taking the shape of the mould.
Cooling and Ejection:
- Cooling lines circulate water or oil to reduce cooling time.
- Once solidified, the mould opens, and ejector pins release the part.
Mould Types and Considerations
Single vs. Multiple Cavities:
- Moulds can have single or multiple cavities.
- Multiple cavity moulds can create identical parts or unique geometries.
Material Selection:
Aluminium moulds are cost-effective but not ideal for high-volume production or tight dimensional tolerances due to inferior mechanical properties.
Efficient High Production:
- Once moulds are developed, the process becomes extremely fast, with cycle times as short as 10 seconds.
- Ideal for medium to high-volume production runs, ranging from 10,000 parts to well over 100,000, depending on the moulds used
Low Cost Per Part:
- Low Cost Per Part:
- For high-output production runs, the cost per part is very low.
- Even for medium volumes (10,000 to 25,000 parts), using aluminium moulds instead of steel helps keep costs down1.
Repeatability:
- Injection moulding ensures you can manufacture identical products consistently.
- Perfect for parts requiring high tolerances and reliability across large volumes1.
Large Material Choice:
- A wide range of plastic materials is available, depending on your part’s properties.
- Beyond plastics, liquid silicone rubber moulding is also an option.
- Fillers can be added to enhance part strength, and a variety of colours are at your disposal1.
Low Waste:
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- Compared to many other manufacturing processes, injection moulding produces minimal waste.
- Any unused or waste plastic can be recycled for future use.
High Detail:
- The process involves injecting molten plastic into the mould under high pressure.
- Complex shapes and intricate details are achievable.
Typically, minimal post-production work is needed due to good aesthetics after moulding