To optimize their operation, many aerospace manufacturers combine multiple parts and materials into one part during the manufacturing process. Depending on the combined part, it may be difficult to use injection molding, and other 3D printing methods such as Carbon DLS may be more appropriate. At TTH, we’ve used Carbon to consolidate multiple parts into one and streamline our client’s operations.

The materials used for this molding process need to have a low shrinkage capacity. The shrinkage required is around +/-0.01” or +/-0.02”. However, many materials can’t reach this range.

Most organizations in aerospace will know whether or not they want to use injection molding for their part. Here are some reasons they may not want to choose injection molding:

Another aspect you should consider when building the tooling is the material. The tooling you create is designed to work with that specific material, and if you need to switch materials, you may need new tooling as well. As we’ve all learned over the past few years, supply chains can break, and the material you're using may not always be widely available.

If you’re interested in this process or other molding processes, message Richfields today. We offer various tooling solutions including precision injection molding. Don’t hesitate to reach out to learn more about how our services can help your next project.

The entire process is automated and conducted through computers through an automatic handling system. It allows the producer to customize the process for the product needed to be molded.

With steel production tooling, you can get extremely tight tolerances as low as +/-0.001". This means you can produce a large number of parts with minimal variance in quality and/or dimensions.

But, what is precision injection molding? It is a highly technical process that makes use of precise molds. It is not used to develop whole products, instead, it develops more complex plastic parts.

A high-precision model is required when creating plastic parts that have tight tolerances. Each part made in a precise injection model needs to be identical. This process can only be applied to plastic parts that are placed and connected with other parts in a fixed form.

Compared to plastic injection molding, this method produces precise plastic parts. It does not mass produce whole parts. These products that are made in the process replace high-precision metal parts from different industrial appliances.

In a similar vein to the above, if you have complex and intricate parts, injection molding may not be the best for you. A 3D printing method may be better, as it can build intricate assemblies that are strong and durable.

Other methods such as additive manufacturing, casting, and machining can help you reduce upfront costs.  Although these methods still may require set up time, molds, or fixtures, the cost of those items may be lower than the injection mold tool. Companies can also amortize the cost of these upfront items, instead of considering them a capital expenditure.

At TTH, a lot of our work with aerospace part manufacturers revolves around interior cabin parts. That said, injection molding can be used for a variety of aerospace parts, from the interior to the exterior, and everywhere in between. Some common applications include:

The plastic components produced in precision injection molding require a tight tolerance. That means that the requirements for the product have precise and accurate procedures. When not followed, it can break inside the mold.

That’s not to say the process doesn't have its drawbacks. With modern advancements in other processes like additive manufacturing, aerospace companies may want to consider other options depending on their circumstances.

Injection molding can work with a wide variety of plastic materials, which is why it has so many different applications for aerospace parts. These materials include:

The materials used for injection molding in aerospace will depend on the part, but there are a plethora of options to choose from, as you’ll see in the benefits below.

To craft the mold, it needs to undergo accurate study, design, and testing. Many elements need to be taken into account for the mold. Here are some of the elements that need attention:

Because of the precise products, the manufacturer should not rely on rapid tools for this method. Precise injection modeling is a slow and steady process that makes a high-precision tool.

By far, one of the primary benefits of injection molding is its ability to produce a large number of parts rapidly. Moreover, this makes the cost-per-part significantly cheaper.

However, it is still possible to combine parts and materials with injection molding. For example, TTH has manufactured armrests for the interior cabins of commercial aircraft. These armrests have a polycarbonate base that’s injection molded first. After that, the part receives another mold that injects an elastomer that binds to that polycarbonate base.

With the ability to use a variety of different materials, injection molding is widely used not only in aerospace but in other industries as well.

Thanks to its ability to produce a large number of parts at low costs with a variety of different materials, injection molding is a very popular manufacturing process for aerospace manufacturers. It can be used to make parts pretty much anywhere, from inside the cabin to the exterior of the plane.

When materials have a high shrinkage capacity, they melt as they undergo the precise injection molding process. It ruins the product in the end.

Precise injection molding can cause plastics to shrink during the manufacturing process. That’s why its materials are different from other injection molding materials.

You can acquire less expensive tooling for lower volumes, but the life of the tool is reduced compared to steel tooling.

This is particularly important for steel tooling. There are other ways to get tooling for less, particularly by using aluminum tooling. However, the best aluminum tooling can usually get you around 20,000 parts. At that level, other 3D printing methods become a competitive alternative.

An example of this would be ABS, a thermoplastic polymer. This kind of plastic can retain its elasticity while going through high temperatures. However, its shrinkage of +/-0.06 is still not appropriate for precision molding. Glass and other resin can be added to reach the desired shrinkage. These help the material absorb the excess heat while keeping the plastic stable.

At TTH, our integrated approach to design, prototyping, and production allows you to bring your concept to market faster and more cost-effectively. We focus on delivering products to your specific requirements, and we hold quality standards for ITAR (International Traffic in Arms Regulations), ISO 9001:2015+AS9100D, and Nadcap.

Injection molding is a manufacturing process that injects molten plastic into a mold (which we often refer to as “tooling”) before rapidly cooling it to produce a large number of parts repeatedly and at low cost.

Now that you’ve answered what precision injection molding is, you can check if you can apply it to some of your products. As stated above, it can also develop a wide variety of complex products.

The precision made during this molding process is achieved through its mold. It needs to suit the design engineering requirements.

One of the drawbacks of injection molding can be its inflexibility. Molds are expensive, and once you’ve created the mold for the part, you'll have to spend a significant amount of money to change them.

To ensure you’re using the best process for you, this article is going to cover some of the primary injection molding benefits for aerospace companies, but also give you other options to consider depending on your circumstances.

TTH’s integrated approach to design, prototyping, and production allows you to bring your concept to market faster, more cost-effectively, than virtually anyone else.

The injection molding process and many of the materials it uses have been around for over a century. It’s a manufacturing method that aerospace companies have tested and proven to be reliable.

Products that are produced in precise injection molding are also comprised of complex geometric parts. These items have specific shapes that are needed for certain items in automotive, pharmaceutical, information technology, and medical fields.

It differs from convection modeling in many ways, from the materials used to the mold created to the machine used in creating the product. This article tackles all you need to know about this technical process. By the end, you can assess if this is the molding process that you need for your next project.

Precision injection models are made with tolerances between +/-0.02” and +/-0.01” or less. All elements mentioned are considered when considering the dimensions tolerance.

Even with the drawbacks listed above, injection molding’s many significant benefits may still make it the best choice for aerospace companies. That said, there are some instances where you may want to consider other options.

Suppliers, such as The Technology House (TTH), have helped aerospace companies produce injection molded parts for years, following AS9100 standards, and verifying material to assure the highest quality standards and repeatability.

Switching to another material, even just an alternative grade, can be difficult in aerospace because of the regulations and testing required for parts and materials. This is already a tedious process, and if you need to change the tooling on top of this, it can increase expenses further.

The injection molding benefits for aerospace are very similar to the benefits of injection molding for other industries.

Polymer optics are used in precise injection molding. This is when CNC machining is used to mold the plastics into precise and calculated shapes. The machines have high pressure that helps improve the quality and precision of the plastic parts. They also manage to repeatedly create an accurate product.

Many molding processes are known to mass produce products that are used in daily life. However, various industries have parts and pieces that are too complex to be made with ordinary plastic injection moldings. A process called precision injection molding is used for such processes.