Precision molding is the latest technology in plastic injection molding. This type of plastic molding is the most sophisticated process of mold design on the market. It may be used for components that require an exceptionally precise form of plastic injection molding.[1]
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Precision injection molding is a highly technical process requiring precision machines and molds. The process of precision molding is different from conventional injection molding techniques and is often used for developing precise plastic parts with complex geometries. These parts are often used as lightweight replacements for high-precision metal parts in industrial applications.
The precision of a part is dependent on the precision injection mold and its suitability for the engineering requirements. Many factors impact the precision injection mold, including:
Injection molding is a cost-effective way to replicate aspheric, spherical, and freeform surfaces and combine them with mounting features. There are three components to successful injection molding:
The mold used to manufacture polymer optics includes the cavity details, optical inserts, and housing to hold the cavities and inserts. Optical and mechanical features may be combined into one platform with polymer optics, which may lead to a mold with high complexity.
Molds are built to the negative of the final part, and the mechanical features of the part are drafted for easy removal once the molding process is complete. Most optical inserts are created from nonferrous alloys that are diamond turned for high accuracy.
Thermoplastics shrink as they cool. The shrinkage is roughly 0.5 to 0.6%, which must be considered when creating the mold.
The optical injection molding machine, called a press, includes a fixed and a moving platen, a clamping unit, and an injection unit. The mold is placed on the press with one half mounted to the fixed platen, and the other half is mounted to the moving platen. Plastic pellets are melted, fed into the injection unit, and injected into the mold.
A clamp mechanism holds the two mold halves together during the injection process. As the polymer cools, it takes the shape of the cavity details and solidifies to create the final optic. Once cooled, the mold is opened and ejects the finished optic.
Injection molding uses complex variables and controls. Without a robust process, even the best mold will experience drift from tool wear, changes in ambient conditions, fluctuations in resin content, and more. This is why it’s essential to find an optics manufacturer with a high degree of skill in scientific molding techniques.
With the proper process, optical injection molding techniques can produce optical components with a high degree of repeatability and accuracy.
Any application that calls for an optical component, such as components for machine vision, scanning, imaging, medical, or general illumination, may use a polymer optic.
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You’ll often find polymer optics in supermarket barcode scanners, LIDAR, automobile sensors, and medical applications. They are also used in sophisticated laboratory equipment like spectrometers, cleanroom particle counters, document scanners, and more.
As applications grow, polymer optics finds its place in telecommunication products and microstructured surfaces such as diffractive optical elements and microlens arrays. Other examples include imaging systems for near-to-eye displays, PC peripherals, and consumer devices like DVD players and smartphones.
Many of these applications are the result of the advantages that polymer optics have over glass components. These advantages are a direct result of the materials and the injection molding process.
Several factors impact the quality of the finished optical component and the repeatability of the process. The design engineering process must include precise guidelines to reduce defects and ensure top quality. Apollo Optical Systems’ molding technology creates consistent, high-quality parts that meet or exceed industry standards for successful finished optical components. Contact us to discuss your custom optics project!
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[1] https://www.sciencedirect.com/science/article/abs/pii/SIndustries worldwide rely on dependable, strong, and accurate components for demanding applications. Precision injection molding offers operations the process versatility, part uniformity, and efficient high-volume production capability to fulfill this need.
Since , Fabrik Molded Plastics, Inc. has served clients in various industrial sectors as a full-service custom injection molding manufacturer. We use engineering-grade thermoplastic resins, innovative injection molding methods, and state-of-the-art equipment to provide our customers with reliable, high-performance components to suit a specific application. Our team takes a scientific approach to building molds and processing parts, offering a competitive advantage to our clients. Learn more about this injection molding method and how the team at Fabrik can support your business with precision injection molding solutions.
Precision injection molding is a manufacturing process with the ability to efficiently and repeatably create components with tight tolerances. Ideal for critical applications requiring uniform, accurate parts, this molding technique can provide consistent quality in medical devices, automotive parts, optics, electronics, and other instrumentation. As an example, manufacturers can mold precision automotive plastics into car parts like bumpers, door panels, throttle bodies, automotive sensors, and more. The process can even create parts that are reliable and durable enough to replace metal components, depending on the properties of the plastic material and part design. Its capability for process control helps ensure high performance in the generated components.
While traditional molding is sufficient for some industry applications, precision injection molding capitalizes on more recent technological advancements that allow for enhanced quality and sealing for high-performance parts.
The main difference between precision and traditional molding lies in the tolerances, or acceptable dimension variations, that are achievable in precision molding. Most conventional molded parts have tolerances of ±0.005 inches, while precision-molded parts are capable of holding tolerances ranging from ±0.002 inches to ±0.001 inches or less.
Plastic injection molding is suitable for manufacturing consistent, affordable, and high-quality plastic parts that have applications in diverse environments or machinery. Manufacturers rely on precision plastic injection molding for the host of benefits the process offers in producing plastic components, including: