Steel and aluminum injection molding are typical examples of metals and alloys used as raw materials for this popular manufacturing process. It is an indication that injection molding is a broader process with more material options.

Plastic injection molding can virtually create anything made of plastics and their polymers. In addition, it is used to fabricate thin-walled plastic parts, used for several other purposes. The commonest of such is plastic housing used to produce various plastic products such as household appliances, insulating parts of electronics, the dashboards of automobiles, etc.

So, with recycled material, even though you may be able to create a good test method, there's no way to create consistency because of the history of the recycled material.

Working with a Tier 1 supplier to a major OEM, there was a discussion with the molders on the floor, people molding the parts on the injection molding machine, and their personal experiences.

Plastics, unlike metals, cannot have any impurities, otherwise they break down chemically, which is one reason their recycling is extremely limited. You cannot have polyvinylchloride (PVC) in with high-density polyethylene (HDPE), polypropylene (PP), polystyrene (PS) etc. This is why we need to address the ‘packaging’ of these products. When you have a PS drink container with an HDPE cap and a PP and/or paper label…how are you going to profitably separate and recycle them all?! You can’t…not on a scale to make it worthwhile. That’s why ‘curbside’ or ‘post-consumer’-based product(s) recycling doesn’t work. You’ve got aluminum foil, in with diapers, in with water bottles, in with milk jugs, in with ballpoint pens, in with….! Anyway, I could go on and on, as I'm extremely familiar with recycling and solid waste management, having founded and run, along with my dad, Resource Recovery Systems here in the U.S., Taiwan, and Mexico for years. I’d love to see plastics recycling become a reality in this country and elsewhere, but a LOT of things have to change before that can actually happen…

Proceed to open the mold once it has cooled. Eject and collect your product as you have completed the injection process. If necessary, the manufacturer can carry out further processing operations like finishing.

We earlier mentioned that other differences exist between die casting vs injection molding other than the materials used. Let’s discuss these differences under the following headings.

The media once called my dad the 'Godfather of San Antonio Recycling' for his life-long efforts at keeping reusable materials out of our landfills and back into usage. Unfortunately that became increasingly difficult to do in the U.S. for a variety of reasons, including that 'recycling' things like plastics is almost impossible to do at the 'household' or ‘post-consumer’ (co-mingled, unreliable, and incompatible) level vs. materials procured from 'industrial' sources. Everything is 'recyclable', but at what cost...?! Is it worth spending $10 to produce something that's only worth $5...?! I like to use the analogy of the $5 bill…if I put a $5 bill on your front doorstep, would you go get it…?! Sure, but if I put the same $5 bill on the steps of the U.S. capitol, would you go get it…?! And why not? See my point…?! As you can see from several recent videos (from India), this type of hands-on recycling is very labor intensive and, thus, not feasible in many countries where labor is not so cheap.

The barrel temperature is often between 300 to 800°F while that of the molds is lower and needs to be well regulated. Passing water around the mold is one good way of regulating temperature. The mold temperature ranges from 150 to 350°F. In die casting, temperature regulation isn’t all that important. The temperature of the mold could be as high as 700°F.

These two techniques – metal injection molding (MIM) and casting, are even more similar than plastic injection molding and casting in that they both use metals. However, they use different metal types. Die casting uses essentially aluminum, zinc, and some other non-ferrous metals. Metal injection molding takes advantage of steel and some other MIM alloys.

The metal alloy used in die casting determines the tolerance of the part produced. Each metal has a standard tolerance rating. Of course, the size and functionality are factors for this. However, die-casted materials tend to have a high tolerance with incredibly high precision.

That said, when choosing between plastic injection molding vs die casting. The first thing is to look at the part’s functionality you intend to fabricate. It simplifies the selection process. Next, you juxtapose the pros and cons of either method to the part’s functionality. Then you can easily decide on which technique is better.

Injection molding is pretty similar to die casting, with the significant difference being the material used. Plastic injection molding uses plastics and other polymers. It is perhaps the most common manufacturing process adopted for fabricating plastics. Polymers commonly used are polyethylene, ABS, nylon, polypropylene, TPU, etc.

It is essential to know that the reclamation process breaks the polymer's molecular structure down, making it lesser quality because the properties of that original polymer have been degraded.  Recycled resin has a smaller molecular weight( length of chains) and varying viscosity, making it unpredictable.  Virgin resin has molecular weight consistency/control with much less variation, giving it consistent properties.

Pressure is another area. The pressure at which molten metal fills the cavity is between 15 to 100 MPa. For plastic injection molding, the pressure is specific to the plastic type.

Due to the high pressure involved in the die casting process, we sometimes referred to it as high-pressure die casting. There are essentially four steps involved in this process.

In other words, there is still no consistency in recycled materials. Until this is addressed, using recycled materials for injection molding must be managed smartly.

Pass the liquefied (molten) plastic materials into the aluminum molds at high pressure. Maintain the high-pressure conditions of the mold as the molten plastic cools, taking the form of the mold.

If you want to produce high-quality machined parts with a sleek appearance, it’s essential to consider some critical factors related to CNC machining.

Also, one video showed recycled materials being used in creating new products, such as pipes and conduit. This is actually not feasible in the U.S. and elsewhere where ‘virgin’ plastics are mandated and recycled input is prohibited. These are the types of things they don’t tell consumers when recycling, especially ‘curbside’, is hyped and then most of the materials collected wind up in landfills anyway. My father singlehandedly built and operated these types of machines for plastics (and cardboard and metals) recycling, but was eventually shut down by the government entities (TCEQ) who supposedly promote recycling but then put hard-working entrepreneurs out of business and redirect all the materials that WERE being recycled into landfills…oftentimes at great distance from their source…NIMBY (Not In My BackYard)!

RapidDirect is the leading provider of die-casting and injection molding services. We boast highly skilled and knowledgeable technicians who have a vast knowledge of these and other related technologies. We offer top-notch services and high-quality die casting parts and injection molding parts at competitive prices to our customers at a fast lead time. In just a short time, we deliver quality.

The typical response to this situation is to combine a certain percentage of recycled material with virgin resin. By combining the recycled materials (uncontrolled variation of molecular weight) with virgin resin, which is very controlled, the blend will allow the process to maintain control, thus allowing the part to meet specifications.  There may be a loss of 5% of the properties, so it will still make and meet standards.

In various industries, die casting and injection molding are two of the most used manufacturing processes. The production of many materials we use domestically, in offices, and other establishments utilized either of these techniques. For example, your kid’s toys and kitchen sink are fabricated with injection molding and die casting, respectively.

While these processes are pretty similar, there are some differences between them. You probably already have a lot of questions. Which is better? Which is cheaper? Or something entirely different. Do not be troubled. Read on as we discuss the die casting vs injection molding comparison in detail.

There are times when both processes are good enough for our intended product. Then we can look at budget constraints, especially when trying to minimize costs. Remember, injection molding is relatively cheaper than die casting. However, the choice is ultimately yours, the manufacturer, as both are great options.

The cost of fabricating a unit product using plastic injection is way cheaper compared to die casting. Notably, it is one of the most cost-effective manufacturing processes. The exciting part is that the larger the number of units you produce, the cost of production gets relatively cheaper. Like in many other production processes, the start-up cost seems high. However, once you have the machine and materials, it is affordable.

Injection molding is the most used technique for producing substances out of plastics. Unlike die casting, it is suitable for the production of large objects. They are used in creating things like kid’s toys, hair combs, wire spools, mechanical parts, plastic tables, and many other plastic products.

There are many benefits manufacturers stand to gain from using the die casting technique. It is essential to know these benefits as they aid in decision-making during the manufacturing process. Some of the advantages include:

However, you are still using recycled material, and 20% of the material has a history of being degraded.  Unfortunately, properties will be lost, influencing the quality of the part.

Dies and molds are shaping tools. The shape of the die and mold used is the form our products take in die casting and injection molding, respectively. Dies aid in shaping molten metals and alloys, while molds shape molten resins or other plastic polymers.

Die casting uses metals and alloys as its raw material. On the other hand, injection molding has a broader range of materials options. Other than plastic injection molding, where plastics, resins, and other polymers are the raw materials, other forms of injection molding where metals are raw materials exist.

The injection molding process involves melting plastics in the injection molding machine. Then, the plastics are passed into the mold cavity in this molten state, usually made of aluminum. During the injection molding process, the plastic resin cools and solidifies, taking the form of the mold used. Therefore, you need an injection molding machine, plastic material, and a mold to carry out this process.

It is not good enough to produce high-precision parts using injection molding. Instead, make use of die casting or other manufacturing processes like machining. In injection molding tolerance of the product is critical when dealing with large-sized products or parts.

After closing the mold, molten metal is injected into the die under high pressure. The high-pressure condition is maintained as the liquid metal rapidly cools, taking the shape of the die.

Prepare the mold for the injection molding process by lubricating it. Spray the mold with an ideal lubricant. Mold lubrication aids temperature regulation within the mold and allows for easy ejection of products after molding.

Reading this piece thus far, you’ve probably noticed that both manufacturing techniques are great options. The questions to answer now include: what process is the best for me? Which is more effective? It’s actually not as difficult as it may seem.

Since the metals are in molten form during this process, die casting is suitable for manufacturing geometrically complex parts. Equipment needed for the method includes a die casting machine with a built-in or separate furnace, where the raw material – the metal is heated to liquid. The metal is usually aluminum, zinc, or copper – essentially non-ferrous metals.

Spray the mold cavity with a lubricant. Lubrication aids in regulating the temperature inside the die and easing the removal of the die-cast. After lubrication, the die is ready for use. Close the mold.

Contact Bozilla Corporation today and let's discuss how we can successfully contribute to your project. Bozilla Corporation’s Injection molding Team has over 21 years of experience analytically and on the floor. We specialize in optimization, consulting, engineering, troubleshooting and Autodesk Moldflow software training. Additionally, our plastics engineers have a full understanding of polymers and how they influence an injection molded part. Your success is our success. Our skilled Team is focused upon meeting the goals and timelines of our customers.

The total costs of die casting consist of labor and equipment. Since the process involves less labor, the cost is essentially a factor of the tools and equipment needed to carry out the operation. For high-precision die casting, the tooling cost is expensive. In fact, they rank amongst the highest of any top-notch manufacturing process.

Frequently, we say the manufacturing process isn’t complete until finishing. However, final products of die casting tend to have a good surface finish. It’s one of the perks of this process. Extra finishing done is merely for aesthetics. Finishes in injection molding, too, aren’t compulsory. Again, however, more frequently done than in die casting.

Chris Czeczuga is a Plastics Engineer, Injection molding expert, Military Veteran and the President of Bozilla Corporation. He has proven success with many Fortune 500 companies throughout the injection molding industry. A graduate from UMass Lowell, he is Expert Certified with Autodesk, has 20+ years of field experience, intimate knowledge of injection molding part, tool and feed system design. Bozilla Corporation's success is built on providing the highest level of injection molding simulation and consulting advice to businesses who have short lead times, require an efficient, cost-effective molding process, and desire to produce a correct part the first time.

During the production process, the steel components of the die are prone to die erosion in the form of them losing their sharp edges. The fine details also tend to lose acuity. All these add up to more tooling costs. You want your product to be in perfect shape. Adjusting designs into something simple is a way of reducing tooling costs.

If you read through the processes of each method as earlier discussed, you would notice they are basically the same, including each step. However, the raw material used and the physical conditions of either technique differ.

Die casting is the manufacturing process that involves casting metal under extreme force. The process involves heating metals into their molten form. Then, the liquefied metal is remolded under high-pressure conditions. This process has been known to man for a long, long time. As far back as the mid-19th century.

Surface finishing options for die casting include anodizing, powder coat, chem film, gold plating, impregnation, etc. These finishes are primarily for increasing aesthetics, durability, thickness, mechanical and chemical resistance. Finishes for injection molding can be grouped into four broad categories: degating, deflashing, cleaning, and decorating.

Although both processes work similarly, there are differences between die casting molds and injection molds. See below for details.

These two are another pretty similar production process. However, the difference is not in the materials used, but in the materials that make up the molds. Die-cast makes use of a metal (often steel) mold, while sand casting, as the name suggests, makes use of a sand mold. That makes it a cheaper manufacturing process. However, die casting is a faster production technique.

Because they are responsible for the quality of the part they are molding, they make decisions (call an audible) and replace the recycled resin with a locally available equivalent virgin resin. This protects them from producing unacceptable.

The industry can adapt by designing parts to accept more variation, allowing increased recycled material content.  For example, the part could be globally or locally thickened to allow for more process variation without loss of part quality.

In the first phase of the plastic recycling process, the material goes through the injection molding process, which partially degrades the material (molecular weight reduction).  Then, it is potentially exposed to UV, temperature fluctuations, or chemicals, which contributes to the degradation process.  Next, the plastic is ground up and typically cleaned with a thermal or chemical process, further degrading the material.  Finally, the reclaimed plastic is ready to, again, be beaten up in the injection molding machine.

Currently, material suppliers are working with recyclers to have test methods put in place to address these issues with recycled materials. The caution is that these test methods reveal the problem vs. fix the problem. How do the recyclers/material suppliers create quality control with regard to molecular weight variation? Suppliers might say they can test the material with an MFR flow test. Unfortunately, an MFR flow test is a zero viscosity test, which does not capture the true shear rate the material will experience during the injection molding process.

Knowledge of the process, the advantage of each other, and the differences between either manufacturing process aren’t enough. Working with the right manufacturing partner is very important!

The numerous comparisons between die casting vs injection molding show that both processes are great options for manufacturing top-quality products. After all, they are two of the most used techniques by many manufacturing industries of the world. Both methods have benefits over the other. Understanding the processes and the pros and cons of either method makes it easy to choose which techniques to use.

It is vital to regulate the temperature in plastic injection molding. The barrel temperature, nozzle temperature, and mold are dissimilar. Inadequate or excessive temperature will lead to flaws in the product.

However, there are better ways to measure Rheology since it is necessary to know the molecular weight variation.  But, there is no way to correctly measure this vital detail on recycled material because there is so much fluctuation in its properties.

As a rule, tighter tolerance leads to higher precision products. However, it is best to follow the industrial tolerance standards when manufacturing products using the die casting process. Die casting products tend to have greater precision and tolerance than those produced by plastic injection molding.

Now, the response in the industry and all industries to using recycled materials is, when possible, to take a certain percentage of recycled material and blend it in with the virgin resin.

As you’d expect, a manufacturing process with its benefits would also have some limitations. Some of the cons of die casting are:

This choice should depend on what you intend to produce. Some say die casting yields superior products. However, plastic injection molding also delivers premium-quality products out of plastic. It all depends on what you, the manufacturer, want.

Once the mold is cool, open the dies to eject and collect each shot. Shots are not the same as castings. A die may contain more than one mold cavity. Each cavity gives rise to individual castings. All the castings from a mold cavity are known as shots.

Die casting is not ideal for materials with high fluidity under high pressure. Also, when fabricating large size parts, use injection molding. However, when manufacturing high-complexity parts that require high precision and accuracy. Then it is a no-brainer. Go with die casting. It is the better choice for such products.

However, it is essential to note that the percentage of added recycled material vs. part quality is not a 1:1 ratio, e.g., adding 20% of recycled resin does not equate to 20% loss of properties.  For instance, you can test the recycled resin of 1 lot of material, and it may meet specs, but the next lot is completely different, thus knocking the process out of control.  This lack of conformity may continue throughout the entire recycled resin being used.

For one of the most used manufacturing processes in fabricating plastic parts, you’d expect it to have lots of benefits. If you think so, you are correct. Below are some of the notable benefits of the plastic injection molding technique.

Die casting is ideal for fabricating medium and small-sized parts with intricate details. It is used to cast industrial and commercial products like faucets, automobiles, hard wares, sinks, gears, etc. Provided the metal parts are not too large, die casting is your ideal choice.

Also, we are an ISO 9001:2015 certified company. Hence, be rest assured that all our materials and techniques are of the best quality. After all, you’d expect nothing less from an industry-leading company. You could also reach out to us for professional suggestions that will help improve your designs.

The extremely high level of precision needed within the aerospace industry makes CNC machining a suitable manufacturing process for the sector.

The processes are virtually the same as those of aluminum injection molding. Other than raw materials, there are other subtle differences. We will discuss them later. That said, how does injection molding work? Below are the processes to follow when fabricating plastic parts using the injection molding technique.

Injection molding, on the other hand, is relatively cheaper. Factors affecting injection molding costs include the raw material and the part’s complexity. However, tuning down design complexity and using finishes only when necessary are means of cutting down the cost.

Degating involves the removal of protrusions and intrusions that would normally disfigure the shape of our product. These protrusions are what we refer to as gates. Deflashing rids the product of all other excesses from the molding process. The finishes aid in improving the product’s shape (or form). Cleaning helps to ensure that the product is spotless – no more extending or protruding plastic materials. Then we can proceed to decoration, especially when we want to increase the aesthetics of our product.