A thermoplastic polymer and member of the Polyethylene family, HDPE is produced from the monomer ethylene. With its high strength to density ratio and a specific gravity of 930-970 kg/m3 it has an excellent weight to strength ratio.

Polycarbonate can experience significant shrinkage as it cools after injection. This can lead to dimensional inaccuracies in the final part. To mitigate shrinkage, adjust mold design for compensation, lower melt temperature to reduce cooling rate, and apply proper packing and holding pressure during molding.

Aim for a minimum wall thickness of 0.040 inches (1 mm) and a maximum of 0.150 inches (3.8 mm) for PC parts. This range supports thin walls and complex geometries.

When designing the gate location for polycarbonate injection molding parts, it’s crucial to prioritize the prevention of weld lines, as they can significantly weaken the part’s structural integrity and harm its aesthetic appearance.

It is used in electronic enclosures, connectors, and components due to its electrical insulating properties and heat resistance.

Due to its strength, low cost and light weight, HDPE is also a popular material selection for: toys, food storage containers, drain-pipes, food preparation products, outdoor signage and household goods.

Polycarbonate comes in several types or grades. Common grade polycarbonates include Medical-Grade Polycarbonate, Food-Grade Polycarbonate, and Generic-Grade polycarbonate.

Have you ever noticed a whitening phenomenon in PVC product whitening? Some of your transparent PVC products, like shower curtains

Here are the typical ranges for some key PC injection molding process parameters for reference. The specifications parameter number needs to be adjusted depending on PC types and grades.

Polycarbonate is used for automotive components such as headlamp lenses, interior trim, and window glazing due to its impact resistance and lightweight properties.

When using ribs for additional strength or support, make the rib thickness between 0.5 and 0.6 times the thickness of the adjoining wall. Avoid using rib heights more than three times the thickness.

Polycarbonate injection molding finds applications in various industries. Especially due to its excellent optical clarity, it is used for eyewear lenses, optical discs, and components in the optical industry. Here are some of the applications.

Polycarbonate is used in lighting fixtures, including diffusers and lenses, due to its optical properties and resistance to UV radiation.

PC serves as an excellent electrical insulator, making it suitable for electrical and electronic components. Some other plastics may not provide the same level of electrical insulation.

Prevent stress concentrations by avoiding sharp corners. Use a corner radius of at least 0.125 inches (3 mm) in PC injection molded parts.

Compared with other plastic injection molding, the polycarbonate injection molding process requires special attention. Our previous blog Principle of Injection Molding Process explains the injection molding process in detail.

How to maintain uniform thickness, read our previous blog to get a comprehensive understanding of wall thickness design guidelines.

PC is known for its exceptional impact resistance. Compared with other plastic materials, It can withstand significant forces without breaking, making it suitable for applications where durability is crucial.

Warping, or deformation of the part after molding, can occur due to uneven cooling rates or internal stresses. Prevent warping by ensuring uniform cooling, using mold design features like cooling channels, and implementing post-molding annealing processes.

Polycarbonate injection molding is the process of injecting melted polycarbonate, a tough, transparent, and heat-resistant polymer, into a mold at high pressure and temperature to create complex plastic parts with excellent optical clarity, impact resistance, and mechanical properties. In this post, we will explore the significance and practical applications of PC injection molding, you will learn its process, advantages, common issues, and design principles.

Optical grade Polycarbonate molded parts are optically clear and have near-total light transmittance and a very low haze factor. UV additives often adapt to PC to protect against direct, long-term exposure to sunlight. By adding flame retardant, polycarbonate can meet the UL 94 standard.

Injection molding flow marks are a common injection molding defect. While flow marks generally do not influence the structural integrity

PC retains its properties at elevated temperatures, making it suitable for components exposed to heat and thermal stress. This advantage is particularly valuable in applications like automotive lighting and electronics, where heat resistance is required.

PC is highly transparent, with optical clarity close to that of glass. This transparency is advantageous for products like lenses, windows, and displays. Many other plastics are not as transparent or may require additional processes to achieve clarity.

Polycarbonate can be sensitive to moisture and high temperatures, potentially leading to hydrolysis and material degradation. Prevent hydrolysis and degradation by thoroughly drying the material, maintaining temperature control, and considering additives or stabilizers to enhance resistance.

For one of our customers, IMI Webber, it was the ideal choice for their specialist, overmoulded, sintered filter.  Its excellent chemical resistance properties made it the best material choice for the automotive environment.  Part of a pneumatic manifold for a 4×4 suspension system, High Density Polyethylene is the perfect candidate and surpassed all other material options.

The injection mold structure and design directly influence various aspects of the final product, including its dimensional accuracy, surface finish,

When designing PC injection molding parts, these guidelines help ensure that PC parts meet end-use requirements and maintain high quality.

Polycarbonate supports a variety of surface finishes, including gloss and high-gloss finishes. Matte finishes can reduce glare, making them suitable for control panel overlays. Non-glossy finishes may be preferred for certain applications like screw caps.

Polycarbonate injection molding is a manufacturing process used to create various plastic parts and components from Polycarbonate resin. The process typically includes steps such as material preparation, mold design, machine setup, injection of the molten Polycarbonate, cooling, ejection, quality control, and the repetition of these steps for mass production. Proper control of temperature settings, injection parameters, cooling, and cycle times is essential to achieve consistent and reliable results in PC injection molding.

PC exhibits resistance to various chemicals, which makes it suitable for applications in chemically challenging environments. Not all plastics offer the same level of chemical resistance.

HDPE, otherwise known as High Density Polyethylene, is this month’s material of the month.  Often regarded the “cheap and cheerful” thermoplastic polymer for plastic injection moulding, like all materials, it definitely has its place.

It is used for eyewear lenses, optical discs, and components in the optical industry due to its excellent optical clarity.

Polycarbonate is employed in medical equipment and devices, including IV connectors, housings, and surgical instruments.

Polycarbonate finds applications in aircraft interiors, including windows, panels, and interior components, where lightweight and high strength are essential.

If you’ve got an idea for a fabulous new product why don’t you get in touch with our product design and development team on 01425 613131 or email hello@becgroup.com, they’ll soon tell you if HDPE is the most product and cost appropriate material selection. But in the meantime, here’s a rundown of pros and cons:

In summary, Polycarbonate injection molding is a versatile and widely used manufacturing process known for its ability to produce high-quality parts with exceptional properties. If you have a project that could benefit from Polycarbonate injection molding, don’t hesitate to explore its potential. Whether you’re in the automotive, medical, or any other industry, Polycarbonate could be the solution you need. For reliable Polycarbonate injection molding services, consider reaching out to Zhongde, your trusted partner in manufacturing excellence.

Polycarbonate, often referred to as PC, is a thermoplastic polymer known for its exceptional characteristics. It has gained widespread recognition in various industries due to its impressive combination of physical and chemical properties.

Incorporate a draft angle, typically ranging from 0.5° to 1° per side, to assist with part ejection from the mold. Adjust the draft angle as needed based on part shape and mold design.

Polycarbonate parts may develop surface defects like blemishes, streaks, or surface haze during molding. Achieve a flawless surface finish by maintaining clean mold surfaces, optimizing processing conditions, and using mold release agents and venting as needed.