Untitled Flashcards Set

Injection Molding

A high-volume manufacturing process for creating plastic parts.

Material Melting

Heating plastic pellets in the barrel until they become molten.

Injection

The process of injecting molten plastic into a mold cavity under high pressure.

Cooling

The process where molten plastic solidifies as it cools inside the mold.

Ejection

The part is pushed out from the mold once it has cooled.

Surface Finish

The aesthetic and functional quality of the surface of molded parts.

Etched Textures

Fine patterns added to the mold surface for matte or textured finishes.

EDM (Electrical Discharge Machining)

A method used for high-precision texturing and rough surfaces.

Integral Finishes

FInishes created directly in the mold.

Added Finishes

Finishes applied after the molding process, such as coatings or painting.

Overmolding

A two-step injection molding process involving the application of a second material over a first.

Multi-Shot Molding

Process allowing multiple materials to be molded together.

Insert Molding

A method where non-plastic components are placed inside a mold before plastic injection.

Outsert Molding

Molding plastic around an existing component instead of embedding it.

Co-Injection Molding

Process where two different plastics are injected into a mold in layers.

Structural Foam Molding

Uses a chemical blowing agent to create a foamed structure inside the plastic.

Gas-Assisted Injection Molding

Technique that uses pressurized gas to create hollow sections in molded parts.

Reaction Injection Molding (RIM)

Involves mixing two liquid thermoset materials that react chemically after injection.

Structural Web Molding

Variation of gas-assist molding that adds hollow sections for improved strength.

Thermoplastics

Plastics that soften when heated and harden when cooled.

Two-Plate Mold

The most common mold type in injection molding, consisting of two halves.

Three-Plate Mold

Contains an extra plate to separate parts from runners during the injection process.

Runnerless Molds

Use heated channels instead of runners to reduce material waste.

Cycle Time

The total time required to complete one injection molding cycle.

Tonnage Rating

Measures the force required to maintain the mold closed during injection.

Plastic Flow

The movement of molten plastic through the mold, directed by runner systems.

Draft Angles

Angles that help facilitate easy part ejection from the mold.

Sink Marks

Defects that occur when thick sections shrink during cooling.

Flash

Excess plastic that forms at the mold seam due to improper clamping.

Blow Molding

A process that creates hollow objects by inflating a heated plastic tube inside a mold.

Extrusion Blow Molding

Melting plastic into a hollow tube, clamping it in a mold, and blowing air to shape it.

Blow Ratio (BR)

The ratio of the final part diameter to the diameter of the parison.

Rotational Molding

A process for creating hollow and seamless plastic parts using low pressure and high heat.

Thermoforming

A process of heating plastic and shaping it using a jig or vacuum.

Vacuum Forming

A type of thermoforming that uses vacuum pressure to pull heated plastic onto a mold.

Amorphous Plastics

Plastics with a random molecular structure, often clear and brittle.

Crystalline Plastics

Plastics with a highly ordered structure, opaque and tough.

Shore Hardness Scale

A scale measuring the hardness of plastics; Shore A and Shore D indicate softness and hardness, respectively.

Tensile Strength

The maximum stress a material can withstand before breaking.

Ductility

The ability of a material to deform under tension.

Thermosets

Plastics that undergo irreversible chemical changes when heated.

Injection Unit

Part of the injection molding machine that melts and injects plastic into the mold.

Cooling System

Monitors the temperature to ensure proper solidification of the molded part.

Ejection System

Pushes the finished part out of the mold after cooling.

Undercuts

Features in molded parts that complicate ejection, requiring special tooling.

Cycle Time and Production Efficiency

Key metrics that determine the effectiveness of injection molding processes.

Surface Quality

The finish or appearance of a molded part, affected by processing conditions.

Multi-Material Components

Parts made by combining two types of material in one molding operation.

Strength and Durability

Key attributes of molded components, impacting their application range.

Material Cooling Rate

Determines the cooling speed of the molten plastic in the mold.

Cooling Rate

Affects cycle time and part quality in injection molded products.

Draft Angle Importance

Essential for part ejection to avoid damage during removal.

Material Properties

Characterizes how materials respond to processing and end use.

Shrinkage Characteristics

Plastics' tendency to shrink upon cooling, which must be accounted for in design.

Joining Methods for Plastics

Various techniques to bond plastic parts, including adhesives, welding, and fasteners.

Impact Resistance

The ability of materials to absorb energy without breaking.

Quality Control in Manufacturing

The processes that ensure the final product meets defined specifications.

Secondary Operations

Post-processing tasks like cutting, drilling, and trimming after mold production.

Design Considerations

Factors to keep in mind when designing parts for manufacturing.

Thermoforming Applications

Use cases where thermoforming offers a cost-effective solution.

Composite Extrusion

A process that combines multiple materials into one extruded profile.

Hollow Plastic Components

Parts created with internal voids for weight reduction and material efficiency.

Thermal Stability

Material's ability to withstand processing temperatures without degradation.

Environmental Considerations

Evaluating material choices and processes to reduce impact on the ecosystem.

Tensile Testing

Determining mechanical properties of materials under tension.

Mechanical Properties

Characteristics related to the material's behavior under load.

Polymer Properties

Attributes defining how polymers perform in various applications.

Vacuum Forming Process Steps

The sequence of operations involved in producing vacuum-formed products.

Material Compatibility

Ensuring materials used in manufacturing work well together.

Production Costs

Factors influencing the overall expenses in manufacturing processes.

Thermal Conductivity

The ability of a material to conduct heat.

Chemical Resistance

Material's ability to withstand exposure to chemicals without degrading.

Recyclability of Thermoplastics

The ability to remelt and reform thermoplastics after their initial use.

Injection Molding Defects

Common issues that arise in plastic injection molding such as flash and warping.

Extrusion Techniques

Methods utilized in the continuous forming of plastic materials.

Blow Molding Design

Considerations that affect the performance and quality of blow-molded parts.

Reinforcement Methods

Techniques used to enhance the strength of plastic parts.

Mechanical Fasteners

Components used to assemble parts together, such as bolts and screws.

Continuous Manufacturing Processes

Production methods where materials are processed non-stop.

Surface Finishing Techniques

Treatments applied to molded surfaces to improve their quality and aesthetics.

Product Design Principles

Guidelines that ensure functionality and manufacturability of products.

Injection Molding Material Choices

Factors impacting the selection of materials in injection molding processes.