plastic injection molding machine

Factors affecting the quality of injection molding

1. Injection pressure: the reason for the need for injection pressure is to offset the resistance in the process of melt flow, or the resistance in the flow process to eliminate the pressure of the injection machine, the two are just the opposite, in order to ensure the smooth progress of the filling environment;

2. Injection time: reasonable injection time is conducive to the ideal filling of the melt, and the ear is very important to improve the surface quality of the product and reduce the dimensional tolerance;

3. Injection temperature: the injection temperature must be controlled within the range of M, the temperature is too low, the plasticization of molten materials is not good, which affects the quality of forming parts and increases the difficulty of processing; If the temperature is too high, the raw material is easy to decompose;

Two, the shortcomings of injection molding process

1, product molding must use injection molding and blow molding two sets of mold and a valve hollow core mold, and the injection mold should be able to withstand high pressure, molding equipment cost is high;

2. The temperature of the injection blank is high, and it needs a long cooling and shaping time after blowing in the injection mold, which prolongs the whole molding cycle of the product and affects the production efficiency.

3. The internal stress of the injection molding blank is large, and it is easy to be subjected to uneven cooling during the transformation of the mold. Stress cracking is easy to occur when producing products with complex shapes and large sizes.

4. The operation skills of the operators are higher

First, the advantages of injection molding process

plastic injection molding machine

1. Injection mold can be used to accurately control the wall thickness distribution of the billet, so that the wall thickness of the container is more uniform, avoiding the thinning phenomenon that is prone to occur in the corner of general blow molding products. The weight of the product can be controlled at +0.1g, the accuracy of the thread can be controlled within the range of 100μM, the mouth size is accurate, and the fine neck product molding precision is high.

2, the obtained products do not need to be processed for E times, no joints, saving the dressing time of the products;

3. The blank made by injection can all enter the blow molding mold, and there is no waste in the process, reducing the waste of forming materials;

4, can get smooth surface products, no scratches, surface text and pattern clear;

5, small batch production can be carried out economically;

6. Wide range of application for plastic varieties;

7, high degree of automation, multi-mode production, high production efficiency.

A clamping unit for an IMM is used to keep the mold shut against the forces developed when injection pressure pushes plastic into the closed mold. It includes a drive mechanism for moving a moving platen of the injection molding machine in at least one direction.

Some think there are only 2 types of clamping units for injection molding, while actually there are 3.

1.Injection Molding Toggle Type Clamping Unit:

A toggle clamping unit for an IMM includes a toggle link, a crosshead connected to the toggle link, and a driving device for driving the crosshead. People mainly use it for high speed injection molding. Due to the different angles to the toggle position has a decelerate interval before the mold touchpoint that can literally give safety to the mold. In comparing with hydraulic-clamping the oil piston of the toggle is smaller, so it can provide a more high-speed in platen moving. And the mold thick adjust is using adjusting nuts to fix the platen, the mold position will always stay at the same point unless change the position.

Clamping Unit in machines

2.Injection Molding Hydraulic Type Clamping Unit：

Advantages:

1.Ideal for producing large volume parts, highly complex parts (automotive industry), high-tech product components with perfect surfaces, or thick-walled parts

2.Good for driving core-pulling and valve sprue

3.Due to the high availability and low cost of spare parts The return on investment is faster

4.There are opportunities for better injection rates, precise injection, and high levels of process stability.

3.Magnetic Type Clamping Unit:

Clamping force generated by a magnetic module in a magnetic mold splint or platen. Plate magnetization, demagnetization, mold closing, mold change can be operated through the interface

 panel.It is easy to use and operate. They give huge advantages through increased efficiency and productivity in a great number of applications even with limited handling.

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plastic injection molding machine

In 1980, France produced the world’s largest screw injection molding machine, with an injection capacity of 170kg. From the 1980s to recent years, the development of injection molding machine is mainly concentrated in several aspects: namely, the application of precision automatic control system and various auxiliary equipment in automatic molding; Precision machinery and high performance hydraulic system; Various special injection molding machine development and computer aided design of complex shape parts plastic flow analysis to determine the best injection conditions; Application of various energy saving technologies in injection molding machine.

Working principle of injection molding machine

Injection molding machine referred to as injection molding machine, injection molding is the use of plastic thermophysical properties, the material from the hopper into the barrel, the barrel outside by heating ring heating, so that the material melt, in the barrel is equipped with external power motor drive rotation of the screw, the material in the double action of the screw shear gradually plasticized, melting and homogenizing, when the screw rotation, Material in the groove friction force and shear force under the action of the molten material pushed to the head of the screw, at the same time, the screw in the material reaction backward, so that the head of the screw to form a storage space, complete the plasticization process, and then the screw in the injection cylinder piston reasoning under the action of high speed, high pressure, the storage room of the molten material through the nozzle into the mold cavity, After the molten material in the cavity is kept under pressure, cooled and solidified, the mold is opened under the action of the mold closing mechanism, and the finished product is ejected from the mold and dropped through the ejecting device.

Composition structure of injection molding machine

Injection molding machine according to the injection molding process requirements is a mechanical and electrical integration of a strong machine, mainly composed of injection parts, closing parts, frame, hydraulic system, heating system, control system, feeding device and so on.

plastic injection molding machine

At present, the common injection molding device has single cylinder type and double cylinder type.

Plasticized parts have two kinds: plunger type and screw type. In the process of continuous rotation of the screw, the plastic realizes the change of physical state, and is finally injected into the mold cavity in a molten state. Therefore, the plasticized component is the core component to achieve uniform plasticizing and quantitative injection.

To provide customers with plastic products development, mold design, product manufacturing and injection molding, its products are widely used in every field of life today, such as household appliances, instruments, wires and cables, building equipment, communications electronics, automotive industry, aerospace, daily hardware and so on.

The overall production process of plastic products is: raw material selection – raw material coloring and matching – design casting mold – machine decomposition injection molding – printing – assembly detection of finished products – packaging factory.

Plastic products are made by injection molding or blow molding, so every time you design a sample, you have to open a new mold, and the mold is generally tens of thousands to hundreds of thousands of dollars, so in addition to the raw material price of plastic products, the cost of the mold is also very large. There may be many parts to make a finished product, and each part needs a separate mold. For example, the trash can is divided into: the barrel body — the lid, the liner, the handle several parts.

Generally speaking, the plastic factory refers to the processing of plastic products with plastic raw materials, semi-finished products and finished products, such as MP3 shell, telephone shell, mobile phone shell, computer monitor shell and other plastic accessories. And finished products such as plastic cups, plastic washbasins, plastic buckets, and other daily necessities. Its essence is called plastic processing plant.

Suction machine will be mixed material into the injection molding machine barrel, heated in the barrel to melt and plasticize state, injected into the mold cavity, cooling in the cavity, demoulding, and then through the ring cutting pad, to complete the injection molding production, this is the injection molding cover production process. So cooling shaping becomes an important part of the molding time of injection products. The cooling water channel is an important part of the mold. Cap quality, speed, mostly depends on cooling water.

In the traditional mold, the cooling waterway is generally processed by CNC, and the cooling waterway can only be processed by the way of drilling through the milling machine to produce the internal waterway network, and through the internal water stop and external plug way to adjust the waterway flow. This leads to the layout of the waterway has great limitations, the waterway can only be cylindrical straight holes, unable to turn around in the mold cavity. When the mold products with complex shapes are encountered, the traditional waterway can not be completely close to the surface of the injection parts, the cooling efficiency is low and the cooling is uneven, resulting in a long injection cycle and large product deformation.

Figure 1:3D model of a traditional waterway
In the beginning of the production of drinks and other plastic caps and claw caps, the traditional waterway is still competent, but with the product packaging more complex, the shape of the cap is more and more unique, uneven shape, resulting in the cooling effect of the traditional waterway is limited.

A New journey: Opportunities for 3D printing to gain innovation
However, with the development of 3D printing technology, especially metal 3D printing (SLM, selective laser melting) technology has been quite mature, and SLM technology has been widely used in aerospace and medical manufacturing industry. In the aerospace sector, GE has verified 35 percent of 3D-printed parts with the verification aircraft, and the C919 has used 3D printed parts on a large scale.

And the bottle cap mold technology, also because of 3D printing ushered in a new life. 3D printing technology, also known as additive manufacturing, is a technology that manufactures solid parts by adding materials layer by layer. Compared with traditional material removal and cutting processing technology, additive manufacturing is a manufacturing method “from scratch”.

For cosmetic bottle caps, this layer by layer 3D printing technology can create an all-powerful cooling water – depending on the shape of the water, it can change according to the shape of the product, anywhere in the mold cavity, there will be no cooling blind spots inside the mold. (as shown below)

Figure 2:3D model and side section of the shaped waterway
Using this water channel, it can make the bottle cap can speed up the cooling speed, shorten the molding cycle of the product, in addition, the cooling balance, reduce product defects, improve product yield.

But can this technological innovation really bring such an advantage to the enterprise? Many people are taking a wait-and-see attitude. In the situation that the author understands, since 2015 through this technology to do mold enterprises spring up one after another, but the quality is uneven, difficult to identify, but whether the enterprise can go to the last or the key to test – technology!

During the three years from 2018 to 2020, there was an enterprise that accumulated a lot and rose against the tide. With their far-sighted strategic vision,

In 2007, Shanghai Yishu Laser Technology Co., Ltd. was established. Through the development and application of 3D printing technology, it is committed to the research and development of injection mold cutting-edge technology, taking the lead in the research of this technology.

Aiming at the two kinds of water channels for the current cosmetics bottle cap mold: traditional water way and following water way, the fast mold flow analyst used Autodesk Moldflow software to analyze the data of the cosmetic bottle cap in the two kinds of water way: insert temperature, cooling time, mold temperature state, etc. To find out if the following waterways really do have a magic effect.

Forms and calculations of thermoplastic molding shrinkage As mentioned above, the factors affecting thermoplastic molding shrinkage are as follows:

1.1 Thermoplastics In the molding process, due to the volume change from crystallization, strong internal stress, large residual stress frozen in the plastic parts, strong molecular orientation and other factors, thermoplastics have a larger shrinkage rate, wide shrinkage range and obvious directivity compared with thermosetting plastics. In addition, the shrinkage rate after forming, annealing or humidification treatment is generally larger than thermosetting plastics.

1.2 Characteristics of plastic parts During molding, the molten material contacts the surface of the cavity and the outer layer is cooled immediately to form a low-density solid shell. Due to the poor thermal conductivity of plastic, the inner layer of plastic parts is cooled slowly and formed a high density solid layer with large shrinkage. So the wall thickness, slow cooling, high density layer thick shrinkage. In addition, the presence or absence of inserts, the layout and quantity of inserts directly affect the direction of material flow, the density distribution and the size of shrinkage resistance, so the characteristics of plastic parts have a greater impact on the size and direction of shrinkage.

1.3 Feed port form, size and distribution of these factors directly affect the direction of the feed flow, density distribution, pressure holding and shrinkage and forming time. The direct feed port and the large section of the feed port (especially the thick section) will be narrowed but the direction is large, and the wide and short length of the feed port will be small. Close to the feed port or parallel to the direction of the feed flow, the shrinkage is large.

1.4 Molding conditions mold temperature is high, melt material cooling slow, high density, large shrinkage, especially for crystallizing material because of high crystallinity, volume change, so the shrinkage is greater. The mold temperature distribution is also related to the internal and external cooling of plastic parts and the uniformity of density, which directly affects the shrinkage and directivity of each part. In addition, the holding pressure and time also have a great impact on the contraction, the pressure is large, long time will shrink but the direction is large. The injection pressure is high, the melt material viscosity difference is small, the interlayer shear stress is small, the elastic bounce after demoulding is large, so the shrinkage can also be reduced appropriately, the material temperature is high, the shrinkage is large, but the directivity is small. Therefore, adjusting the mold temperature, pressure, injection speed and cooling time and other factors can also be appropriate to change the shrinkage of plastic parts.

Mold design according to the shrinkage range of various plastics, plastic parts wall thickness, shape, feed port form size and distribution, according to experience to determine the shrinkage rate of each part of the plastic parts, and then calculate the cavity size. For high-precision plastic parts and difficult to master the shrinkage rate, the following methods are generally suitable for mold design:

(1) Take a smaller shrinkage rate of the outer diameter of the plastic parts and a larger shrinkage rate of the inner diameter, so as to leave room for correction after mold test.

(2) Mold test to determine the form, size and forming conditions of the pouring system.

③ To post-treatment plastic parts after the post-treatment to determine the size of the change (measurement must be in the demoulding 24 hours after).

(4) Correct the mold according to the actual shrinkage situation.

⑤ Re-test the mold and can appropriately change the process conditions slightly modify the shrinkage value to meet the requirements of plastic parts.

2. Liquidity

2.1 The fluidity of thermoplastics can be generally analyzed from a series of indexes such as molecular weight, melting index, Archimedes helix flow length, performance viscosity and flow ratio (process length/plastic part wall thickness). Small molecular weight, wide molecular weight distribution, molecular structure is poor, melting index is high, screw flow length is long, viscosity is small, flow ratio is large, the flow is good, the same name of the plastic must check its instructions to determine whether the flow is suitable for injection molding. According to mold design requirements, the fluidity of commonly used plastics can be roughly divided into three categories:

① Good fluidity of PA, PE, PS, PP, CA, poly (4) methyl shicene;

② Medium fluidity polystyrene series resin (such AS ABS, AS), PMMA, POM, polyphenyl ether;

③ Poor liquidity PC, hard PVC, polyphenyl ether, polysulfone, polyaromatic sulfone, fluorine plastic.

2.2 The fluidity of various plastics also varies due to various forming factors. The main influencing factors are as follows:

(1) When the material temperature is high, the fluidity increases, but there are also differences among different plastics. The fluidity of PS (especially impact-resistant type and high MFR value), PP, PA, PMMA, modified polystyrene (such AS ABS, AS), PC, CA and other plastics changes greatly with the temperature. For PE and POM, temperature increase or decrease has little influence on its liquidity. So the former in the molding time to adjust the temperature to control the flow.

(2) The pressure injection pressure increases, the molten material is subject to shear action, and the liquidity increases, especially PE and POM are more sensitive, so the molding time to adjust the injection pressure to control the liquidity.

③ The form, size, layout, cooling system design, flow resistance of molten material (such as surface finish, feed passage section thickness, cavity shape, exhaust system) and other factors directly affect the actual flow of molten material in the cavity, where the molten material to reduce the temperature, increase the flow resistance, the flow will be reduced. Mold design should be based on the fluidity of the plastic used, choose a reasonable structure. Molding can also control the material temperature, mold temperature and injection pressure, injection speed and other factors to properly adjust the filling situation to meet the molding needs.

plastic injection molding machine

3. Crystallinity

Thermoplastics can be divided into two categories: crystallized plastics and non-crystallized (also known as amorphous) plastics according to the fact that no crystallization occurs when they condense.

The so-called crystallization phenomenon is the plastic from melting state to condensation, the molecules from independent movement, completely in an unordered state, into molecules stop free movement, according to a slightly fixed position, and there is a tendency to make the molecular arrangement into a regular model of a phenomenon.

As the standard to distinguish the appearance of these two types of plastics, the transparency of the thick wall plastic parts is determined by the general crystalline material is opaque or translucent (such as POM, etc.), amorphous material is transparent (such as PMMA, etc.). However, there are some exceptions, such as poly (4) methyl hiopene is a crystalline plastic but has high transparency, ABS is amorphous material but not transparent.

plastic injection molding machine

In the mold design and selection of injection molding machine, we should pay attention to the following requirements and precautions for crystallized plastics:

(1) The heat required to rise to the molding temperature is much, and the equipment with large plasticizing capacity should be used.

(2) When cooling back, the release of heat is large, and it should be fully cooled.

③ The proportion difference between molten state and solid state is large, forming shrinkage is large, and shrinkage holes and pores are easy to occur.

④ Fast cooling, low crystallinity, shrinkage, high transparency. The degree of crystallinity is related to the wall thickness of plastic parts. The wall thickness is slow cooling, high crystallinity, large shrinkage and good physical property. So crystalline materials should be required to control the mold temperature.

(5) Significant anisotropy and large internal stress. The uncrystallized molecules after demoulding have a tendency to continue crystallizing, and are in a state of energy imbalance, prone to deformation and warping.

⑥ Narrow crystallization temperature range, easy to occur unfused material end injection mold or plug the feed port.

First, the selection method of injection molding machine

We should check the product specification provided by the injection molding machine manufacturer. The specification has the performance parameters of the injection molding machine, including the type of raw materials, the quality (weight) of the products, the shape design size and so on. You can sort out what kind of parameters you need, and then compare with the parameters of the injection molding machine, the value is close to the injection molding machine is worth choosing.

In addition, we also need to understand the processing accuracy, production speed and product accuracy of the injection molding machine, to see whether it meets the molding conditions of the product. In order to facilitate the mold assembly, the spacing size of the tie rod should be greater than the width and height of the mold. The size of the injection molding machine template should conform to the size requirements of the molding mold when it is installed and fixed.

Two, injection molding machine operation items

There are many operation items of injection molding machine, which can carry out the selection of injection process action, feeding action, injection pressure, injection speed, ejection type, the control of the temperature of each section of the cylinder, the adjustment of injection pressure and back pressure. Operation items of injection molding machine mainly include three aspects, that is, control keyboard operation, electrical control cabinet operation and hydraulic system operation.Injection Machines Molding

Three, the molding process of screw injection molding machine

The working principle of injection molding machine is similar to that of syringe, which is a cyclic process. Its flow is: quantitative feeding — melting plasticizing — pressure injection — filling cooling — opening and taking out parts — removing plastic parts — closing the mold — and carrying on the next cycle.

The specific steps are as follows:

1. Add granular or powdery plastic into the barrel, and process the plastic into a molten state by rotating the screw and heating the outer wall of the barrel.

2, the mold closing and injection seat forward steps, so that the nozzle is close to the mold gate passage.

3. Put the pressure oil into the injection cylinder, push the screw forward, and inject the molten material into the closed die with lower temperature at a higher pressure and faster speed.

4, such as plastic curing molding, open the mold out of the product.

1.  Making interchangeable cores mold : a most effective and cost-saving manufacturing process. Suitable for customers looking for “more variety but less quantity” solution. With only one mold, it can efficiently generate different kinds of products,

2.  Making high transparent PC, Acrylic, PMMA, PET.. parts mold with high gloss polishing and Mold-Tech texture on parts surface, applied mostly in lighting parts, outdoor LED parts projects.

3.  Making gas assisted injection molds and products projects …mostly applied in projects like the thick handles, monitors, the frame of TV cabinet etc, which prevents the shrinkage mark, improves the strength of the parts and saves material costs.

4  Medical silicone and rubber molds/products making : We manage both “solid” and “liquid” silicone rubber material meeting the standard of RoHS, and REACH,  and can be applied like skincare parts, medical earplugs, nipple pacifier, check valve, diving mask.

Injection system function: injection system is one of the most important parts of injection molding machine, generally there are three main forms: plunger type, screw type, screw preplastic plunger injection type. The screw type is the most widely used. Its function is that in a cycle of the plastic injection machine, a certain amount of plastic can be heated and plasticized within a specified time, and the molten plastic can be injected into the mold cavity through the screw under a certain pressure and speed. After injection, the molten material injected into the mold cavity should be fixed. See Figure 1

Composition of injection system: injection system is composed of plasticizing device and power transmission device.

The plasticizing device of screw injection molding machine is mainly composed of a feeding device, a barrel, a screw, a gluing component and a shooting nozzle. The power transmission device includes the injection cylinder, the injection seat mobile cylinder and the screw drive device (glue motor).

A motorcycle helmet is a type of helmet (protective headgear) used by motorcycle riders. The primary goal of a motorcycle helmet is safety – to protect the rider’s head during impact, thus preventing or reducing head injury and saving the rider’s life. Some helmets provide additional conveniences, such as ventilation, face shields, ear protection, intercom etc.

Plastic Helmet Manufacturing Market Outlook

Growing head injuries due to road accidents still remain the major factor driving the global market. However, manufacturers are concentrating on not only improving the quality of helmets but also making them stylish. This is expected to benefit the global market for motorcycle helmets in the near future.

Currently, the full-face helmet segment dominates the global motorcycle helmets market, state the analysts. The increasing number of head injuries can be credited for the growing demand for full-face helmets. China two-wheeler helmet is forecast to grow at a CAGR of around 25% through 2022.

Market growth is anticipated on account of rising awareness among consumers for safety coupled with introduction of advanced safety features in two-wheeler helmets. Moreover, increase in sales of luxury or premium two-wheeler vehicles coupled with rising per capita income is further expected to boost helmet sales in India during the forecast period.

The off-road or motocross helmets are popular among the biker groups whereas open face or ¾ helmets are commonly used by the daily riders. With advancements in the technology, leading players are consistently manufacturing a wide range of motorcycle helmets. The global Motorcycle Helmets market is valued at 1670 million USD in 2017 and is expected to reach 1730 million USD by the end of 2025, growing at a CAGR of 0.5% between 2018 and 2025.

Global Premium Motorcycle Helmets

Global Premium Motorcycle Helmets Market is expected to grow at a CAGR of 10.4% during the forecast period. Rising demand for premium helmets because of an increase in the number of riders and technological advancements, strict enforcement of helmet laws across nations are the factors boosting the market growth. However, high cost of products is expected to hamper the market growth.

Based on material, carbon fiber segment is expected to be the significant growth due to modern premium bike helmets are increasingly being made of carbon fiber, which provides a higher tensile strength, a fact that gives the rider much more safety.

Europe is the largest market because of the continuous increase in the motorcycle permits in several European countries. Asia Pacific is projected to be the fastest growing market as manufacturers are producing bikes at relatively affordable prices.

The target market for premium helmets constitutes people who have relatively high disposable income and ride motorcycles for recreational or leisure activities. As such, the developed markets, Europe, North America, and Japan are the major markets for premium helmets worldwide. Recent studies have found a direct correlation between the price of the helmet and the safety it provides.

The premium motorcycle helmets market is segmented by the material used in the making of helmets as Kevlar, Carbon Fiber, Fiber Glass, Plastics. By geography, the market is segmented as North America, Europe, Asia-Pacific, Latin America, and Africa & Middle East. Europe is the largest market worldwide because of the continuous rise in the motorcycle permits in several European countries. Asia- Pacific is forecasted to be the fastest growing markets followed by China and India.

Global Safety Helmet Manufacturing Market

The global safety helmet manufacturing market to reach USD 3.19 billion by 2025,driven by the rising awareness among the employees about safety, surge in the construction sector in developing economies, and strict safety norms mandating the use of protective gear. Increasing industrialization and growth of the construction industry in countries such as India, China, Mexico, Brazil and South Africa is also expected to create demand for safety helmets.

Asia Pacific is expected to grow at a CAGR of 5.5%, in terms of revenue, over the forecast period due to an increasing demand for safety helmets in construction and manufacturing industries. In addition, significant infrastructure spending for existing & new structures in Europe is expected to add to the growth of the market over the forecast period.

Global Safety Helmet Market Revenue, By Application,2014-2025 (USD Million)

In 2017, the global Road Bike Helmet market size was million US$ and is forecast to million US in 2025, growing at a CAGR of from 2018. The objectives of this study are to define, segment, and project the size of the Road Bike Helmet market based on company, product type, application and key regions.

Plastic helmet making machines are mostly as below:
1. Plastic helmet injection molding machine
2. Helmet injection mould
3. Material dryer or hopper dryer
4. Material Mixer
5. Materail auto-feeder ( vacuum feeder )
6. Product take out Auto-robot
7. Runner cut off robot
8. Product conveyor

Below we will try to introduce the pen manufacturing industry step by step.

Firstly, we should know the pen components & ballpoint pen parts’ names. Most of ballpoint pens will mostly have parts like pen barrel, pen clip, pen tip, thrust device, thrust tube, spring, reservoir, socket, ball & ink.

But there are lots of simple design ballpoint pens with quite fewer parts, these ball point pen parts names are pen barrel, pen end clip, reservoir, socket, ball & ink.

Secondly, we would like to talk about the manufacturing process.  Most of  ballpoint pen making process as below:
1. Making the ink: Large batches of ink are made in a designated area of the manufacturing plant.

2. Stamping and forming:
1). While the ink is being made, the metal components of the pen are being constructed.
2). The formed pieces are then cleaned and cut. They are immersed in a bath to remove oils used in the molding process.

3. Molding the housing:
1). The plastic components of the pen are constructed simultaneously with the Ballpoint Pen’s other pen pieces.
2). For pieces that have more complex shapes, like caps, ends, and mechanical components, injection molding is used.

4. Ink filling and assembly:
After the components are formed, the assembly can take place. Typically, the ballpoint is first attached to the ink reservoir.

5. Final assembly, packaging, and shipping:
The point and reservoir are then placed inside the main body of the pen. At this stage, other components such as the cap and ends are incorporated. Other finishing steps, such as adding coatings or decorations or performing a final cleaning, are also done. The finished pens are then packaged according to how they will be sold.

In this article, we would like to introduce more details about the ballpoint pens` plastic parts manufacturing.  As it`s most people want to know when entering the ballpoint pens manufacturing industry or business. As we know, most ballpoint pen manufacturers produce the ballpoint pen`s plastic parts themself and then bought the ball point pen refill from a big manufacturer.

So what ball pen manufacturing machines you may need if you want to produce the ball pens? The answer is plastic injection molding machines is the main pen maker machine. As it can be used to produce most of ball pen plastic parts like pen barrel, pen clip, pen tip, thrust device, thrust tube, pen end plug, cap, adapter, etc.

Ball pen making machines will include many machines to set up the pens manufacturing production line:
1. Plastic injection molding machine
2. Plastic injection molds
3. Plastic materials
4. Material hopper dryer
5. Material auto feeder/vacuum loader
6. Water tower/chiller

Plastic Pen Barrel Manufacturing Sample

Videos for Ballpoint Pens Manufacturing Application Samples

How the Spring Ballpoint Pen Works

The automatic ballpoint pen is a commonly used tool in daily study and office. Press the refill to extend and lock the ballpoint pen, and then press the refill to retract into the pen holder, which is simple and practical. How does an automatic ballpoint pen work?

Structural composition: The components of the automatic telescopic locking mechanism of the ballpoint pen include: locking parts, pressure rods, and guide rails, as shown in the following figure:

The upper and lower tooth columns of the automatic ballpoint pen (for the time being) are the upper tooth column that can be pressed by hand, and the lower tooth column that can be rotated inside. The meshing of the upper and lower tooth columns is incomplete, only the tip of the tooth is partially engaged, and the guide ribs behind the two engaged teeth are designed to slide in the same guide groove, and the lower tooth column is pushed down by the upper tooth column. After the groove, due to the action of the spring, the teeth of the lower tooth column will slide along the inclined surface of the teeth of the meshing upper tooth column, so that under the action of the inclined surface, the lower tooth column will turn an angle and slide to the other side. , it is pressed down, and this repetition can realize the function of the ballpoint pen. I don’t know if the expression is clear or not. It’s best to observe the ballpoint pen carefully to confirm my statement.

Ballpoint Pen Manufacturing Molding Machine`s Standard Configurations

Moulding Machine`s Standard Configurations

Clamping Unit

* Mechanics and electrical safety protection
* Euromap 18 interface for robot
* Automatic centralized lubrication system
* Low-pressure mold protection
* Machine cover on clamping unit full closed protection
* Automatic mold thickness adjustment
* Automatic clamping force adjustment
* Hydraulic drive gear for mold adjustment
* Clamping/Injection /Ejecting  transducer
* Ejector backward reset function

Injection Unit

* Double-injection cylinder
* Double-carriage cylinder
* Linear guide rail
* Nozzle purge cover with a visible window
* Low-speed high-torque Hydraulic motor
* Screw speed detective sensor
* Nitriding steel screw & barrel
* Anti-cold start-up of screw
* Automatic resin clear function
* Proportional back pressure control
* Multistage barrel PID temperature control
*  Material molten & injection fault defection

Hydraulic System

* Third generation servo pump system
* Low noise energy saving hydraulic circuit
* Two set sets core puller valve
* Two set sets core core valve
* Oil temperature indicator & alarm
* Oil level meter indicator & alarm
* Low-pressure clamping function
* Quick-clamping
* Mould height auto adjustment
* Back-pressure control function
* Auto Suckback function
* Pressure relief valve for carriage moving
* Exposed high pressure tubing with explosion -proof chain
* Multi-set water distruibutor with fast plug
* Nozzle moving function

Electric and Control System

* Mirle controller (Keba, Techmation is optional)
* Multi-language (Chinese and English, Spain, etc)
* Data lock and operation password
* SPC quality management
* Alarm and parameter resetting the record
* PID temperature direct control
* Screw & Barrel protection function
* Support current/voltage analog output
* Clamping force auto-adjust
* CAN, I/O point interface
* Multi-level password protection
* Quality data process control interface

Get Pen Manufacturing Machine Price Now

The following articles will cover plastics helmets manufacturing production, various materials used to build motorcycle helmets and they all have different advantages. Helmets have several layers. The outer shell features a reinforced Styrofoam lined interior and a breathable padding that offers the perfect fit and moisture absorption. Because inner padding or foam layering tend to be more uniform across the helmet spectrum, these articles will focus on the commonly used materials for the exterior shell. The helmet is usually composed of a hard shell, a buffer layer, a comfortable cushion, a wearing device, and goggles, etc. The hard shell is mainly made of resin materials of PC, ABS, PC+ABS alloy materials, glass Fiber, and carbon fiber materials, etc.

What are safety helmet production process

Plastics helmets manufacturing will involve many parts of helmet manufacturing process and and helmet manufacturing machines. The helmet manufacturing process is mostly includes injection molding the child parts, buffing & sanding, painting & decals, attaching the visors & straps, multiple qualingly checks and then packing & shipping.

What are safety helmets made of?

The hard shell is mainly made of resin materials of PE, PC, ABS, PC+ABS alloy materials, glass Fiber, and carbon fiber materials, etc.
The goggles are mostly made of PC.
The buffer layer is made by foam normally.
The wearing device or pads is manufactured by PE for most.

China announced the policy of “One Helmet, One Belt” since this April. Zhejiang and Jiangsu released relevant regulations for riding safety. The regulations strongly pulled the helmet selling and production in China, and even has increased 3,500 new companies for this big market within one month.

Are helmets the same?

The helmets are not the same. There are many kinds of helmets, such as Full-face, Open face (3/4), Half, and Modular (flip-up) helmet and so on. In terms of safety, the Full face type is best, and the Half one is the worst. So the helmets is absolutely not the same, there are different safty helmets with different safty standards.

What are safety helmets standards?

DOT: Standards determined by the U.S. Department of Transportation. The DOT rating currently in effect is federal standard FMVSS 218, and any helmet with the DOT sticker should meet these standards (more on that later).

ECE: Standards determined by the Economic Commission for Europe. This multinational standard is used by more than 50 countries in Europe, and any helmet with this sticker must meet the current ECE 22.05 standard.

SNELL: Standards determined by the Snell Memorial Foundation. This is a voluntary testing procedure, and is only required by certain race bodies. The current standard is SNELL M2020 for street use.

FIM: A relatively new standard, the FIM rating is used for helmets that meet safety criteria established by motorcycling’s global racing organization for track use.

SHARP’s: The Safety Assessment and Rating Programme is a UK non-profit organisation that is part of The government.
SHARP’s impact test is the most complex of all standards. It uses seven helmets for impact tests. Six of the helmets are tested at 6 m/s, 7 m/s, and 8 m/s on the front, left, right, top, and back of the helmet with flat anvil and blunt anvil impact tests.The final helmet will be subjected to oblique friction impact tests at two points left and right.
The final impact results were calculated to determine the helmet star rating, with 5 stars as the highest rating and 1 star as the lowest rating.

What are helmet manufacturing machines

To produce the plastic helmet will need many kinds of helmet manufacturing machines. The most main parts is the plastic helmet shelles, it is made by an helmet injection molding machine. Which is the main plastics manufacturing machine. And the goggles and the wearing pads will be produced by the injection molding machine as well.

Plastic Helmet Parts Manufacturing Solutions

Plastic Helmet Part Picture	Plastic Helmet Part Name	Helmet Parts Material	Helmet Parts Molding Cavity	Injection Molding Machine Size (Click to check details )
	Helmet Shell	ABS ABS+PC	1 Cavity	300 ton Injection Machine
			2 Cavity	420 ton Injection Machine
	Helmets Visors Helmets Goggles	PC	1 Cavity	210 ton Injection Machine
			2 Cavity	420 ton Molding Machine
	Helmets Cushions	PE HD EPS	1 Cavity	210 ton Plastic IMM
			2 Cavity	420 ton Plastic IMM
	Wearing device Reflector	PP PC	16 Cavity	170 ton Injection Machine
			32 Cavity	420T Plastic Molding Machine
* We reserve the right to make changes as a result of further technical advantages.

Plastic helmet making production machines are mostly included below machines & auxiliary equipment:
1. Plastic helmet injection molding machine
2. Helmet injection mould
3. Material dryer or hopper dryer
4. Material Mixer
5. Materail auto-feeder ( vacuum feeder )
6. Product take out Auto-robot
7. Runner cut off robot
8. Product conveyor

The helmet production line will also need some factory basic machines and auxiliary equipment linke water tower, cooling chiller, air compressor, etc. These machines are the basic parts support of a plastic products manufacturing factory. Or called factory three basic infrastructure water, electric, air.

Plastic helmet shell mold Information ( Sample project )

[This post contains video, click to play]

Guanxin Plastic Machinery is one of the leading molding machines manufacturer in China. We offer our customers turnkey solutions for plastics products like helmets manufacturing plants machines. You can contact us if you have any ideas for making helmets.

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Crystal cosmetic bottle injection molding production line is very simple. Though the flow rate of acrylic is worse than PS and ABS, and the melt viscosity is more sensitive to temperature changes. During the Cosmetic Bottle injection molding process, we can adjust the injection temperature to find the best melt viscosity. PMMA is an amorphous polymer, which melting temperature is greater than 160°C and the decomposition temperature is up to 270°C.

1. Acrylic Material Processing Before Injection Molding

The acrylic has a certain degree of water absorption about 0.3-0.4%, but the injection molding process needs about 0.1% to 0.04%.
It will causes bubbles, gas lines, and reduced transparency in the melting if the moisture is high. So the acrylic must be dried before injection molding.

Normally, the drying temperature is set between 80 to 90℃, and the drying time is at less 3 hours.
Recycled materials can be used 100% in some cases. The actual percentage depends on the quality requirements, usually about 30%.
Recycled materials should avoid pollution, otherwise it will affect the transparency and the properties of the finished product.

2. How to Select a Right Injection Molding Machine

PMMA has no special requirements for injection molding machines. Because of its high melt viscosity,
It need a screw with deeper groove and a nozzle with larg diameter hole.
A screw with a larger L/D ratio should be used for low-temperature plasticization if the product needs higher strength.
In addition, a hopper dryer should be picked for acrylic cosmetic bottle injection molding.

3. Acrylic Injection Mold

The mold temperature should be set as 60℃- 80℃. The diameter of the main runner should match the inner taper. The best angle is 5° to 7°.
If you want to inject 4mm or more products, the angle should be 7°, and the diameter of the runner should reach 8 to 10mm, the overall length of the gate should not exceed 50mm. For products with wall thickness less than 4mm, the diameter of the runner should be 6-8mm.

For products with wall thickness greater than 4mm, the runner diameter should be 8-12mm. Diagonal, fan-shaped and tabular gate depth should be 0.7 to 0.9t (t is the thickness of the product wall), and the diameter of the needle gate should be 0.8 to 2mm; smaller size should be used for low viscosity.

The common vent hole has a depth of less than 0.05 and a width of 6mm, and the demolding slope is between 30′-1° and 35′-1°30° of the cavity part.

4. Melting temperature

It can be measured by the air injection method: ranging from 210°C to 270°C, depending on the information provided by the supplier.
Withdraw the back seat, make the nozzle of the injection molding machine leave the main runner bushing, and then manually carry out plasticization injection molding, which is air injection molding.

5. Injection temperature

Fast injection can be used, but to avoid high internal stress, it is advisable to use multi-level injection, such as slow-fast-slow, etc. When injecting thick parts, use slow speed.

6. Detention time
If the temperature is 260℃, the residence time should not exceed 10 minutes, if the temperature is 270℃, the residence time should not exceed 8 minutes.

Guanxin Plastic Machinery have lots of experience in the PET preforms manufacturing process. We offer our customers professional PET preform production line with lots of optimized functions, manufacturing process management, production management and quality control systems. We provide you a turnkey solution for full process of Dehumidification Drying raw materials, quantitative additive color mixing machine, rapid and stable injection molding output of bottle preform, PET preform mold with hot runners, rapid cooling robot mechanism; Total production cost down with high productivity, and lowest blow bottle defect rate of only 0.5%.

This PET Preform Production Line is mainly set up by a 350 ton PET preform injection molding machine with servo motor and electronic gear box Synchronous Charging system, and a 64 cavities high speed PET preform injection mold with Hot runner system. At the same time, the PET preforms manufacturing production need below auxiliary equipment as well:

N0. Auxiliary Equipment
（1）Dehumidifier（nmaterial）
（2）Heat-consistent Hopper Dryer
（3）Hopper Dryer Stand
（4）Double-layer Silicone Pipe
（5）Auto-cleaning loader
（6）Vacuum Autoloader with Indicator
（7）Vacuum Autoloader with Electric Sensor
（8）Suction Box with Stop-Valve
（9）1.5 inch Heat-Resistant Steel Pipe
（10）2 inch Heat-Resistant Steel Pipe
（11）Water Chiller for PET preform Mold
（12）Dehumidifier for PET preform Mould
（13）Cooling Tower
（14）Pump for Cooling Tower
（15）Conveyer
（16）Preforms Tank

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20 Liter Plastic Paint Bucket is a bit special as the thickness is about 1.85mm but the material flow path is about 600 mm. It means the flow path is more than 300 times comparing it`s thickness. So the manufacturing process requires a high injection speed. We will need a optimized Plastic Bucket Moulding Machine to produce the 20 Liter Plastic Paint Buckets.

20L plastic paint kettle is most made with only one cavity with a 650 Ton dedicated injection molding machine. This plastic paint kettle molding machine should have a high injection speed of about 500-600 mm/s, the open stroke should be bigger than 750mm, with a precise mold open controlling system if you may run an in-mold-labeling system in the future.

Click here to check more details for the plastic bucket injection molding machines.

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