Wish for extreme part complexity to improve aesthetics? CNC machining can do this but bill your budget due to longer production times, longer cycle times, and the consumption of more material, ultimately resulting in higher costs.

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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.

The incurring of tooling costs plays a crucial role in the determination of the injection molding cost. Here are the parameters on which a whole stake in tooling costs relies.

The higher the mold cavity, the more pressurizing power and time a tool requires. As a result, the reduction in production speed increases the injection molding cost.

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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.

As you have heard a lot about many misconceptions, like injection molding would be very expensive, they are not true in the fullest sense.

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.

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.

Steel materials and CNC machining are good for medium- and high-volume production. But manufacturing in high volume reduces the cost per part manufactured compared to medium-volume production.

Injection molding is a favorite technique for plastic manufacturers in the mass production of many plastic parts or components. The rise in demand for this manufacturing technology makes it a crucial factor in running the plastic industry.

If you attempt to incorporate the injection molding technique for a huge production, there is no doubt that it will bring many benefits, including cost-effectiveness as one of them.

In this way, it is very essential for you to determine the injection molding cost before the inception of your assembly line to produce products.

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.

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.

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The material mentioned here refers to the material of the mold and the material of the product. Most designers are well versed in the materials of their products. Injection molding harnesses mostly thermoplastics (PEEK), and it is very affordable. For example, it can cost between $1 and $5 per kilogram. How to select the right material for injection molds is also very important.

Part DFM analysis is very beneficial in terms of reducing errors and part costs and boosting productivity and efficiency. It is because it ensures that CAD design is optimized for assembly and manufacturing.

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.

Material cost=[(1 Material loss) * Product weight * Batch adjustment loss Material weight Normal scrap rate * Product weight * Batch] * Material unit price/Batch

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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.

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.

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.

The material loss is generally 3% -5%; The weight of materials lost during machine adjustment and the weight of normal scrapped products are generally 5000g –15000g

Injection molding costs would be expensive or affordable; it is your choice and your tendency toward research and calculation. If you try to do your research and optimize these crucial factors in accordance with your requirements, you could minimize confusion.

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.

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.

Whether you start your injection molding for a low, medium, or high production volume, each one has its own pricing factors.

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.

Mostly steel and aluminum are preferred by manufacturers. Aluminum molds are lightweight, rust- and heat-resistant, and highly formable. Steel molds are good for high production and where high durability is in demand, although they are expensive.

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This article unveils everything related to the calculation of the injection molding cost in order to make you knowledgeable and informed. Ready to get aware of how much injection molding costs? Be calm and stay with us.

The larger the part size, the bigger the injection molding machine, and the more sophisticated the mold manufacturing procedure. As a result, the higher the injection molding cost.

If your demand is for low-volume manufacturing, go for 3D printing technology and aluminum material in order to get low costs for injection molding.

3D printing is the best choice for complex geometries at affordable pricing, whereas CNC machining is great for very hard complex geometries, although it would be costly. EDM machining is relevant for creating a mold from hard and conductive materials.

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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)!

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Although it is very popular among industrialists, no one can deny that some misconceptions and facts exist about the cost of injection molding. This technology may prove expensive if you do not know how to optimize various interlinked elements and factors.

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Mold Trail Cost: Large and medium-sized molds can be controlled within 3%, and small precision molds can be controlled within 5%;

Processing cost=(machine adjustment time/batch forming time/number of mold holes) * Injection molding machine worker salary

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.

It is right to say that it would prove costly if you harnessed it for a small quantity of production instead of mass production.

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Mold design for complex components demands high costs and skilled expertise. It is the outcomes that you pay for in an injection molding project.

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.

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.

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…