How to Expand The Lifespan of Injection Molding?

Expanding the lifespan of injection molding can be complicated as it depends on various factors, but it is achievable. The quality of the parts of the injection molding machine is impacted by a mold with a short lifespan and insufficient precision. Thus, it is important to enhance the lifespan of injection molding. In this blog, we will discuss how to expand the lifespan of injection molding.

Let’s find out how to expand the lifespan of injection molding.

Ways to Expand the Lifespan of Injection Molding

The following are a few ways to expand the lifespan of injection molding:

Choose the  Best Quality Raw Material

Plastic raw materials with outstanding process performance are typically chosen to mold products based on achieving service performance and product quality standards, which is not only beneficial to the molding of products but also advantageous to the extension of mold life.

The Structural Design can Extend the Lifespan of Injection Molding

When examining the mold's service life, a structural design with high durability, stiffness, and ease of repair can increase the mold's service life. The choice of cavity wall thickness for developing small and medium-sized injection molds centers on the strength requirements.

To avoid excessive distortion during the working process, the cavity wall thickness of a large die should be estimated and checked in strict conformity with the stiffness parameters. The mold's thermal equilibrium must be preserved via the mold design.

The gating system, temperature regulation system, and exhaust system can all be designed sensibly to limit the potential for hot cracks in the mold and lengthen the mold's useful life.

Choose the Best Quality Mold Materials and Heat Treatments

The cavity of an injection mold is typically complicated, with strict specifications for precision and surface quality. The element for the mold should be chosen so that it not only satisfies the customer's criteria for the quality of the product but also takes into account its price, cycle durability, impact resistance, resistance to high temperatures corrosion resistance, and other work needs.

The molding grade and die life of plastic components can be enhanced by using plastic die steel with outstanding mechanical qualities and good processability. Additionally, the heat treatment process should be logically organized, and the parameters should be strictly regulated during the mold-making process.

Select the High-Precision Method of Machining

To guarantee the precision of the machine, You can choose the highly accurate machining technique. For a longer mold lifespan, you can select wire cutting, NC machining, or EDM. The mold service life can be extended by enhancing the mold cavity surface, corrosion resistance, lubricating qualities, and wear resistance.

A correct setup and scheduled maintenance can lengthen the life of an injection mold. The grinding feed can be decreased. Additionally, it can stop the development of grinding cracks and excessive grinding heat.

By Proper Coating of Physical Vapor Deposition (PVD)

The PVD coating can extend the life of the mold. Tool material becomes stronger and corrosion-resistant thanks to PVD. Additionally, it provides less surface energy to aid in the ejection and release of mold components. In PVD, the source material is ionized to create a high-energy material.

The coating utilizes a variety of alloys, including carbides, titanium, and oxides. Lubricity and hardness are utilized by zirconium nitride and provided. That necessitates the correct release of mold components. Additionally, it keeps tolerance. 

It works on a variety of materials. like printing aluminum, steel, stainless steel, steel CNC machines, and plastic parts. Mold life can be extended by PVD coating. Additionally, it helps to safeguard your expenditure and downtime.

By Proper Mold Processing and Surface Treatment

The seamless connection of the fillet radius, straight line, and arc at the size transition must be properly ensured during the cutting of the mold. It is possible to choose a coarse-grained grinding wheel with a powerful cutting force or a grinding wheel with a weak grip, and the grinding feed can be suitably reduced to minimize grinding overheating and grinding cracks.

The cleanliness of the mold's working surface must be extremely high for the injection mold due to the demands of the plastic surface quality, corrosion resistance, and demolding. In the meantime time, the parts' surfaces experience wear and mold bonding, and strain and fracture frequently begin at the surface.

Choosing Good Quality Steel and Heating Requirements

The mold service life is also impacted by the material choice. Excellent mechanical qualities in steel do more than just enhance the quality of molded products. However, it also supports a longer mold service life. A mold-making company's top priority is superior-quality steel. Verify that the steel you choose can meet all needs and criteria. such as the need for cleaning and corrosion resistance.

Invest in inexpensive steel. It guards against further harm to the substance. The process of nitrification may be successful in raising surface hardness. The die life will also be extended. The life of the mold is significantly impacted by appropriate heat. Therefore, it is necessary to monitor and adjust the heat conditions. It benefits the production of injection molds.

Epilogue

Improvements in several variables affect the uniformity of injection mold life such as the construction of molds, polishing, structural design, upkeep, material, coating, and surface organization. The life of a plastic injection mold can be extended using certain actions and activities. by selecting the proper raw material and using the correct pressure, temperature, and mold design. It might be feasible if mold technology advances.

Contact MING-LI to know more about the tips and tricks for expanding the lifespan of injection molding.