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Injection mould, also known as injection mold, is a specialized tool used in the injection molding process to form plastic materials into specific shapes. It typically consists of two main components: a fixed cavity half and a movable core half, which close to create a cavity where molten plastic is injected, cooled, and solidified into the desired part.

INQUIRY

Requirements and Considerations for Injection Moulds Based on Material Characteristics

Engineering Plastics (e.g., ABS, Nylon, Polycarbonate)

Material Properties:

Engineering plastics offer moderate heat resistance, good mechanical strength, and varying flowabilities. They may shrink during cooling (e.g., Nylon has a higher shrinkage rate than ABS) and require controlled processing temperatures.

Mould Requirements:
⦁ Temperature Control: Moulds need efficient cooling channels to ensure uniform solidification and minimize warping, especially for materials like Polycarbonate (PC), which demands precise temperature management to avoid internal stresses.
⦁ Surface Finish & Release: Polished mould surfaces reduce friction for easy part ejection, while demoulding angles must be designed to prevent sticking, particularly for sticky materials like Nylon.
⦁ Wear Resistance: Materials like Nylon with fillers (e.g., glass fiber) can abrade mould surfaces, so moulds may require hardened steel (e.g., H13 tool steel) to extend lifespan.

Special Engineering Plastics (e.g., PEEK, PPS, PTFE)

Material Properties:
Special plastics feature extreme heat resistance (e.g., PEEK up to 260°C), chemical inertness, and high viscosity, but they often require higher processing temperatures and have lower flowability.

Mould Requirements:
⦁ High-Temperature Resistance: Moulds must use heat-treated alloys (e.g., stainless steel or tool steel with nickel plating) to withstand prolonged exposure to high temperatures without deforming or corroding.
⦁ Precision Cooling & Heating Systems: Complex cooling channels (e.g., baffle or conformal cooling) are essential to manage rapid solidification of high-viscosity materials, while preheating systems may be needed to prevent material degradation.
⦁ Corrosion Protection: For chemically aggressive materials like PTFE, mould surfaces may require coatings (e.g., chromium or PTFE itself) to resist erosion and ensure part release.
⦁ Rigid Structural Design: Special plastics often demand higher injection pressures, so moulds must have robust frames and clamping systems to prevent flash or deformation during the process.

Summary

Injection mould design must align with the thermal, mechanical, and rheological properties of engineering and special plastics to ensure part quality, production efficiency, and mould longevity.

Key considerations include material compatibility, temperature management, wear resistance, and structural rigidity, with specialty plastics generally requiring more robust and specialized mould solutions.