This is a complex process and it takes highly trained individuals to oversee the entire process.  At APL while it is important to keep output levels high safety is also a primary concern.

It is from the wall thickness of the part and the thermodynamic properties of the plastic that the cooling time can be estimated.

The last stage is ejection from the machine. This is done with an ejection system. When the mould opens the part is pushed out, Force must be used because the part shrinks and sticks to the mould. The mould can be shut again after ejection and another shot can be injected for the process to begin again.

Plastic pellets are fed by means of a hopper into the injection moulding machine. These pellets move towards the mould by the injection unit. The heat surrounding the barrel and the pressure serve to melt the pellets.  The volume of material injected is called the ‘shot’. This injection time finished when 95%-99% or the mould is filled.  It is hard to calculate exactly the injection time because the flow of the plastic is always changing and dynamic.  Injection time can be estimated by other factors such as injection pressure,power and shot volume.  The injection pressure can range from 35-140 MPa. The rate of injection and the pressure which can be reached are determined and controlled by the hydraulic system in the machine.

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Self skinning foam, molded EVA foam or reticulated foam are all highly appreciated for their properties. Our original XL EXTRALIGHT® foams are unique and will meet your highest expectations.

APL, A Comar Company, School Rd, Lugduff, Tinahely, Co. Wicklow, Y14 HE29 Tel:+353 (0) 402 38231 Email: info@automaticplastics.com

Before the mould is injected with material, both halves of the mould have to be closed. They are closed by a clamping unit. Both halves are then attached to injection moulding machine and one half can slide.  Material is then injected as the clamping unit pushes the halves together and both halves are held tightly while material is injected. Larger machines (machines with more clamping power) take longer to close and clamp the mould.

The cooling process involves the plastic inside the mould beginning to cool after it makes contact with the interior mould. As the plastic cools when it hardens it will take the desired shape.  The part may shrink slightly during cooling. Only when the cooling period has elapsed can the mould be opened.

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We are the North American and world leader in XL EXTRALIGHT® reticulated foam, with specific formulations for heat, abrasion, fire resistance and shock absorption. The Foam Creations team is always ready to assist you in selecting the best injection molded foam material for your custom foam molding projects.

Comar, Headquarters, Comar, 220 Laurel Road, Voorhees, NJ 08043, US Tel:1-800-962-6627 Email: info@automaticplastics.com

Mould design is a key factor in determining the quality of the finished product. The strength, durability, shape and size all rely on the type of mould that is used. The mould must be sturdy and be able to withstand the pressures involved during the injection process. The polymer must also be able to flow properly along the mould. The mould must also be carefully designed to allow heat transfer to control the cooling process.

At Automatic Plastics we do our very best to offer quality plastic parts across a wide range of industries using this process. Contact APL regarding your injection moulding needs we’re very happy to talk with you regarding your requirements and can offer you a highly competitive quote.

The synergy between foam injection molding XL EXTRALIGHT® material and product design is the key in terms of foam molded products development success. At Foam Creations, our chemist team is focalised to develop new formulations of XL EXTRALIGHT® material adapted to your needs. Over the last 20 years, we have developed and produced dozens of our first-class closed-cell foam injection molding XL EXTRALIGHT® formulations, with a wide range of great properties. Our reticulated foam material is greatly superior to regular self skinning foam and EVA injection molded foams. XL EXTRALIGHT® is free of phthalates, heavy metals, latex, making them very safe.

Injection moulding involves a high pressure injection of a polymer into a mould where it is shaped. The individual parts of this process are very short. The whole injection moulding process usual lasts from 2 seconds to 2 minutes.  There are four stages in the cycle. These stages are the clamping, injection, cooling and ejection stages.

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