Injection Pressure: In typical ABS injection molding, the injection pressure generally falls within the range of 50-100MPa. This pressure range is often suitable for achieving the desired results.

Skill Gaps: As automation takes over, the most valuable skill sets among experts are rapidly going down, and soon, there will not be anyone left with the knowledge of designing unique products in injection molding. The cost of training new people is also high for many companies and turning to automation is ultimately the only option left for many of them.

These heat-resistant ABS variants have found wide-ranging applications in the fields of electronic appliances, home appliances, and automobile parts. Their ability to withstand elevated temperatures ensures product longevity and reliability in settings where heat tolerance is a prerequisite.

People use plastic products at every turn in their daily lives. Be it in packaging their food or the tools they use, one way or another, they have to rely on plastic products. Injection molding is the easiest way to turn any plastic material into a usable object, and the following are the most common products you are most likely to come across today.

Pollution: The one thing plastic has never been able to fully address is pollution. It takes very long for plastic to degrade, and in some cases that never happens. The first plastic material ever made is still intact to this day. There are efforts to find alternative plastics, but so far, nothing has been found that’s as efficient as plastic.

A huge part of vehicles is made using plastic injection molds. Not every part of the car is made using metal, as that would add unnecessary weight. To counter that, there are parts like the dashboard, radio controls, cup holders, seats, increasing every day a lot of other elements that are made using plastic and injection molding is the best way of getting the right shapes. The same applies to heavy machines. They have parts that are not involved in the heavy lifting that is made using solid plastic injection molds. The advantage of using molds for all these parts is that they are easy to replace, and they help bring down the overall weight of cars and machines.

In some scenarios, opting for modified ABS or alternatives such as PC (Polycarbonate), PC/ABS blends, or PP (Polypropylene) might be more suitable, as each material offers different advantages and disadvantages based on the application’s needs. The right choice of material is key to ensuring product performance and safety.

Recommended Drying Conditions: The recommended drying temperature for ABS is in the range of 80-90℃, and it’s advisable to maintain this temperature for a duration of at least 2-3 hours. This process ensures that the material’s humidity remains below 0.1%. Neglecting to dry ABS adequately can lead to issues such as water mist and silver streaks on the product’s surface.

Despite the great success it has enjoyed over the years and the continued growth in manufacturing, injection molding is not without some challenges. The following are the most notable ones so far.

The use of some types of plastic materials as an alternative for construction has been ongoing for years now, and it’s getting better and better, thanks to injection molding. Parts like roofing, roofing vents, and deck fasteners can be made cheaply and after using plastic materials, and this can bring down the cost of construction significantly without impacting the structural integrity in any way. The other advantage is the choice of colors that one can choose from since plastic can be molded in any shape, design, and color depending on the personal preferences of the client.

Varying the monomer ratios yields ABS with diverse physical properties, catering to specific application needs. Furthermore, incorporating additives like glass fibers bolsters strength, while flame retardants enhance fire resistance. These adjustments highlight the adaptability of ABS, enabling its utilization across various industries for an array of specialized purposes.

Thermoplastic Polyurethane: This is a soft and elastic type of plastic that is used for things like phone and laptop cases. It is soft, elastics, and has great tensile strength. It is mixed in with rubber, and this is where it gets its rubbery and elastic properties. It performs very well in extreme temperatures and is a good material for making power tools, sporting goods, and cable insulations.

While ABS plastic offers numerous advantages, understanding its disadvantages is crucial for appropriate application. Here’s a concise overview of the main disadvantages of ABS plastic:

These flame-retardant ABS variants are engineered to adhere to stringent safety standards while maintaining the versatility and processability that ABS is renowned for, making them indispensable for applications where fire resistance is paramount.

Understanding the distinct characteristics and application-specific benefits of each ABS variant enables manufacturers to make informed decisions based on their particular production requirements.

No other products have benefited greatly from injection molding than toys. Unlike other items, they don’t require complex construction; they simply have to attain certain shapes and be lightweight at the same time. Injection molding is the only way to make toys of all kinds and shapes at very rapid paces. Another advantage of making toys using injection molding is the safety aspect. The parts are made whole without any small splinters, and this is ideal for babies as it reduces the risk of toy parts getting swallowed by accident.

Demand: The demand for plastic products, deposit the ravaging effects on the environment, is at an all-time high, and this has made meeting the demand a challenge for many injection molding manufacturers. The cost of upscaling has been too much for many companies, and this deficit has led to a lot of problems in the industry as a whole.

Acknowledging these disadvantages of ABS plastic is essential for its selection, taking into account the specific application environment, safety requirements, and cost-effectiveness.

In addition to the previously mentioned ABS variants, there are several other specialized types to consider, such as glass fiber-reinforced ABS, anti-static ABS, and light-shielding ABS. The choice of ABS type should align with your specific requirements and intended applications.

Notably, ordinary ABS plastics retain their toughness even at temperatures as low as -40℃ and can withstand a temperature range of -40℃ to 80℃.

Importance of Drying: While some factories may skip this step for low-quality ABS products, it’s crucial to understand that ABS requires proper drying before injection molding.

ABS, owing to its unique properties and processing capabilities, finds extensive applications across various industries.

Draft Angle: Reasonably designed draft angles are crucial to prevent surface strain. Inadequate draft angles can lead to cosmetic imperfections in the molded part.

There are a lot of clear plastic products made through injection molding that is used to store and package food at all levels. Perishable foods and drinks are naturally stored in airtight plastic bottles and containers to increase their shelf lives. Besides packaging, there are also a lot of products used for food preparation that is made using injection molding; this includes high-temperature serving pans, bread trays, NSF food service products, among many others.

Attention to these critical factors in the mold design and injection molding process will help ensure the production of high-quality ABS parts with the desired surface finish and physical properties.

In summary, ABS injection molding, with its diverse variants catering to specific application requirements, offers a versatile solution across various industries.

Standard ABS may lack resilience in high-temperature environments, readily deforming when exposed to heat sources like a hair dryer.

Nylon: Also called Polyamide, nylon is the most commonly used raw material in injection molding as it is widely available and easy to extract from petroleum-based products. It is malleable with low melting temperatures, and this makes it the perfect material to use for all kinds of uniquely shaped products. Nylon can be used to make strong and solid mechanical parts like gears and bushings for automotive parts as they are able to counter wear and tear as well as chemical resistance.

The range of household goods that are made using injection molding cannot fit here. Anything you can think of can be reproduced to the exact measurements using injection molding. From utensils, flower pots, wire ties, air freshener units, to plastic chairs, to other types of furniture, decor, containers, and so many more. Since people spend more time in their houses, many injection molding companies have specialized in the creation of household goods only due to the high demand that’s ever-increasingevery dayy.

Gate Design: The type and location of the gate significantly influence surface quality. Inadequate gate design may complicate post-processing. Thoughtful gate placement is essential.

We are going to explore these questions and more. We will take a deep dive into the world of injection molding, look at the raw materials used, the CNC machinery and the technologies involved as well as the challenges facing the industry and how it will shape itself for the future. If you have always been curious to know about injection molding and what it really entails, then stick around to the end.

We cannot do without plastic, at least not yet, and that’s the stark reality facing the world right now. The best that we can do is to find more sustainable ways of deadlines with what has already been released into the ecosystem, but that too will take time. If you wish to know more about plastic injection, the behind-the-scenes process, and the things that can be made from it, check out our website when you have the time and have all your questions answered by our team of experts.

Polyoxymethylene: This is a special type of acetal resin that is primarily used for making mechanical and automotive parts that would, in most cases, require metallic parts. This type of plastic raw material is very strong, tough, and rigid and, when made in the right design, can be used as movable parts in a car for a very long time without affecting the performance of the structural integrity. Polyoxymethylene is used in the making of gears, knife handles, fasteners, ball bearings, among many other parts

Molding temperature: Considering the melting temperature of ABS being 170 to 180 ℃， the injection temperatures typically range from 200 to 230°C for ABS, with variations among ABS types. Caution is needed to avoid excessive heat, which can lead to plastic decomposition. Mold temperatures generally range between 50 and 80°C, but for high glossy products, higher mold temperatures are necessary.

Polycarbonate: Polycarbonate is the material you see on compact discs with a shiny and colorful surface. This is the material you go for when you want something that’s stronger than acrylic. It has a predictable form, and this gives people a precise dimensional control that can be maintained all through the injection molding process. However, it is not suitable for food storage or for making closed containers as it is too brittle.

Ordinary ABS can be susceptible to combustion, emitting strong flames, dark smoke, and a pungent odor during the burning process. It also produces harmful byproducts, including carbon monoxide and hydrogenated chlorine.

Materials as Alternatives to ABS: While ABS holds a prominent position in the world of plastic manufacturing, other materials such as PP and PC/ABS also serve as viable alternatives for producing shell parts. While PP is a cost-effective alternative, its inferior gloss, hardness, and toughness compared to ABS may limit its application in certain contexts.

The softening temperature (viscoelastic transition temperature) of ABS lies between 85 to 95°C, and its melting temperature (viscous flow temperature) is between 170-180°C. Therefore, its high-temperature resistance is not very good.

Attention to mold quality, appropriate drying treatment, and meticulous control of injection parameters are vital for achieving superior surface quality and overall product performance.

Transparent ABS, also known as MABS or methyl methacrylate-acrylonitrile-butadiene-styrene plastic, is engineered by blending ABS with PMMA, resulting in a transparent and durable material.

This has become very evident in the last 12 months the pandemic caused many hospitals to be over capacity. Injection molding is also preferred in making medical tools as there’s more flexibility when it comes to product design. You can create any size and shape of medical tool as you deem fit, depending on the type of molding machine at your disposal. Some common products include disposal bins, wall mounts, medication trays, among many others.

Injection Speed: Optimal injection speed often falls within the medium to high range. Adjusting the injection speed within this range can help maintain the quality and integrity of the molded ABS parts.

ABS lends itself to various processing methods, including injection molding, extrusion, blow molding, and foam processing. Its surface is amenable to plating and painting, and the material is weldable, expanding its utility across diverse applications.

Notable grades include 757F, 737 (Chimei), 2802HD, 2802-TR (BASF), HP20, HP30 (Sabic), 920 (Toray), and SX-200 (Asahi). Food-grade ABS is essential for various culinary and food processing applications, guaranteeing the highest standards of safety and compliance.

Some hardy tools can be fashioned out of plastic for use in the agriculture sector with ease. The advantage of switching to plastic molded tools is that they are durable, can withstand extreme temperatures, and are way much cheaper to make compared to other materials. Many farmers around the world are using plastic tools and equipment for most of their small tasks around their farms that don’t require heavy machinery.

Flammability: A notable disadvantage of standard ABS plastic is its flammability. It tends to burn, producing a lot of black smoke, limiting its use in applications where high fire resistance is necessary.

The medical sector is another area that makes use of injection molding to fashion out all kinds of products that are vital in saving the lives of patients. Things like syringes and drug containers have to be made using plastic as they are cheaper and safer compared to other materials. They can also be manufactured in bulk, meaning that there’s a constant flow of supplies that far outstrips the pace of their use.

To understand how plastic molding products are made, it is vital that you know the type of raw materials that go into their construction, as that will give you a clear picture of how they are used—some of the most common raw materials used in the making include the following.

Electrical components require ample insulation to make them safe for use around the house and workplaces. The best way to do this would be to create housing that fits them the right way before being sold to consumers. Injection molding is the best and the fastest way to get electrical housings of any shape and size in large numbers. Some electrical components that require plastic housing include TV remotes, computers, TVs, among many others.

Injection Speed: In the ABS injection molding process, an overly low injection speed can result in insufficient plastic density and poor gloss on the injection molded part. Adjusting the injection speed to an appropriate level can enhance surface quality.

2. Automotive Industry: The automotive sector extensively relies on ABS for an assortment of applications. ABS is commonly employed for crafting interior parts, contributing to the overall aesthetic appeal and structural integrity of various components. Additionally, it finds use in the production of engine peripheral parts, where its impact resistance and malleability are valuable assets.

Food-grade ABS meets stringent FDA certification standards, ensuring its safety for direct contact with food. These ABS variants are free from harmful substances, making them ideal for food-related applications.

Understanding the unique advantages and contexts of these materials is crucial for ensuring optimal performance and quality in various manufacturing processes.

ABS, a copolymer of acrylonitrile, butadiene, and styrene, derives its properties from these constituent materials. Acrylonitrile contributes strength, chemical resistance, and thermal stability, while butadiene enhances toughness and impact resistance. Styrene imparts high gloss, easy coloring, and smooth processing.

Low Heat Distortion Temperature: ABS plastic has a low heat distortion temperature, making it prone to softening in high-temperature environments. The low softening and melting temperature of ABS means it is not ideal for applications near heat sources or hot machinery parts.

Plastic bottles make up the bulk of all plastic products in use today. From packaging water to soft drinks and chemicals, among other things. They are the most manufactured injection molding products that can be found in every retail shop and beyond. Plastic bottles are the easiest to make, and getting the raw materials needed for their manufacturer is also quite easy. This is the reason why they are made in such huge numbers.

With its diverse variants catering to specific application needs, ABS continues to demonstrate its adaptability and resilience, solidifying its position as a cornerstone in the world of plastic manufacturing.

If you have specific material needs or require guidance in selecting the most suitable ABS variant for your project, please feel free to reach out to us. We are here to assist you in making informed decisions and ensuring the right material for your unique applications.

Adhering to these recommendations for drying treatment and injection parameters is vital to produce ABS parts that meet quality standards and avoid common surface defects associated with moisture and incorrect injection conditions.

Holding Pressure and Time: Inadequate holding pressure and a short holding time may result in poor density and gloss. To address this, it is important to increase both the holding pressure and holding time during the injection molding process.

Polystyrene: Polystyrene is the material used to make hard and durable toolboxes and other containers for power tools. It is one of the hardest forms of plastic and is a very reliable material when it comes to making hardy containers. The other advantage is the cost of making them; despite their hardiness, it costs way less to make them compared to other types of plastic materials. The only drawback is that they are very bad for the environment.

Based on the level of impact resistance, ABS can be classified into three categories. Each category has its own advantages and uses, and it’s not always the case that higher impact resistance is better.

ABS, or Acrylonitrile-Butadiene-Styrene, is a versatile and widely used amorphous plastic material that results from the copolymerization of three key raw components. This remarkable material boasts an array of exceptional properties, making it a preferred choice for a diverse range of applications.

3. Toy Manufacturing: ABS is a staple material in the toy industry, renowned for its strength and versatility. Popular toys, including the iconic Lego building blocks, utilize ABS for its ability to withstand substantial impact and maintain intricate shapes.

Acrylic: Acrylic is used for products that are transparent, and for this reason, you will find it in transparent walls, lighting equipment, among many others. Acrylics are a very good alternative for glass as it is stronger, meaning it cannot be shattered by any kind of force. It is also quicker and cheaper to make, and the color options are so many. It is also scratch-resistant and can withstand any type of weather without sustaining any damage. Another advantage of acrylic is that it doesn’t contain the toxic chemical called Bisphenol A, which is responsible for food poisoning. This is the reason why acrylic is best suited for food containers.

Poor Weather Resistance: A significant disadvantage of ABS plastic is its low weather resistance, especially when used outdoors for extended periods. It ages quickly under UV exposure, resulting in yellowing, powdering, and increased brittleness, which limits its outdoor use.

Polypropylene: This is another thermoplastic material that is used in making food storage containers. It is widely used in the packaging industry as it is not toxic and doesn’t let any chemicals from outside sip into the content of the package. It can also be subjected to extreme conditions like hot water without getting degraded. It also has a very high tolerance for chemicals and moisture with one of the most incredible elasticities, impacts strength and toughness.

Thermoplastic Rubber: This is a mix of rubber and plastics, and they are used for making medical tools like catheters, suspension bushings, headphone cables, among many others. It is one of the easiest materials to use in injection molding due to its low melting temperatures. They have an outstanding tolerance against extreme weather conditions, heat, and chemicals, and the great impact strength they have makes them one of the most durable injection molding materials you will ever come across.

Cooling: For thick-walled plastic parts, inadequate cooling can lead to surface imperfections and reduced luster. Having a properly designed wall thickness and improving the cooling system is vital to maintaining product quality.

Cost of Automation: Automation is the future and the only way that most injection molding companies will be able to keep up with the rising demand is by switching to industrial robots for their operations. The stumbling block, how warm is that the cost of setting this up is too huge even for the most established brands. Production will have to take a significant hit for any form of automation to be pulled off.

Chemical Stability Issues: ABS plastic’s resistance to certain chemicals like acids, alkalis, and oils is relatively weak, leading to potential corrosion or dissolution. This factor must be considered when ABS is used in environments exposed to harsh chemicals.

Mold Surface Quality: A paramount factor is ensuring the mold’s surface quality. The absence of scars, micropores, friction marks, or roughness is critical. Smoothing the cavity’s surface, and if necessary, utilizing chrome plating for polishing, can greatly enhance the final product’s appearance.

As of the first quarter of 2021, the market size value of injection molding was $284.7 billion. That sheer number is all the proof you need to know how massive injection molding has become integral in the manufacturing economies around the world. With plastic products forming most of the daily-use items, it is not a surprise that injection molding continues to grow every year. But what exactly are these products that are made using this process? How and where are they used?

With a density ranging between 1.05 to 1.18g/cm3, ABS exhibits a shrinkage rate of 0.4% to 0.9% and a hygroscopicity of less than 1%.

Prominent brands that produce transparent ABS include 920 (Toray), TR558, 557 (LG Plastic), and Chimei’s PA-758 (Chimei Taiwan). This specialized ABS variant is favored for applications where transparency is a key requirement.

ABS plastic is celebrated for its non-toxic and odorless nature, rendering it safe for various applications. Its visual appearance typically manifests as ivory translucent or transparent granules or powder.

Acrylonitrile Butadiene Styrene: Also called ABS, this is an opaque thermoplastic polymer that is tough, with good dimensional stability, high resistance, with good anti-breaking and tearing attributes. The material also has a very low melting temperature, and this makes it ideal for quick changes. The material is mostly used to make casings and insulation for electronic parts like phone adapters, socket guards, and keyboard keys.

In contrast, heat-resistant ABS offers a solution with various grades capable of withstanding temperatures up to 120 ℃ without deformation or degradation. Notable examples include 777B, 777D, 777E from Chimei, HJ730 from Samsung and H2938 from Kumho. These grades are celebrated for their exceptional heat resistance, mechanical strength, and electrical insulation properties.

1. Home Appliances and Office Equipment: ABS is prominently used in the manufacturing of structural parts for a wide array of home appliances. These include juicers, rice cookers, kettles, and hair dryers, where the robustness and aesthetic appeal of ABS play a pivotal role. Similarly, in office equipment, ABS is often the material of choice for crafting typewriter casings, keyboards, and router casings, ensuring a balance of durability and design.