Precision begins with the design phase. Our engineering team thoroughly reviews part drawings, evaluating them for molding and tooling issues. We examine features that may pose challenges for molded plastic, such as undercuts, texture requirements, draft angles, and thickness. By addressing these concerns early on, we ensure that the final design will meet the required form, fit, and function while optimizing the manufacturability of the part.
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To simplify the tooling process, IMS engineers utilize the principles of Design for Manufacturing (DFM). By employing intelligent mold design strategies, we can achieve complex geometries using simple precision tooling methods. Our goal is to engineer cost-effective tooling solutions while maintaining the highest levels of precision and delivering on customer requirements. By collaborating closely with toolmakers, we guarantee that the tooling is precisely crafted to meet the specific requirements of each project. We also perform routine maintenance and upkeep on each precision mold to ensure mold longevity.
Our injection molding process is guided by an unwavering commitment to precision and consistency. Customer satisfaction is our primary goal, and we ensure that the tools and processes we use serve that goal. We utilize hydraulic and hybrid hydraulic electric machines that offer exceptional precision, as opposed to an injection molding machine focused solely on speed. By leveraging our expertise in process control and material behavior, we can achieve precise and consistent results.
From the very beginning of a project, IMS engineers identify the key parameters required to establish and maintain consistency throughout the manufacturing process. We adjust injection mold temperature, material temperature, injection speed, and injection pressure to optimize the mold cavity filling and ensure the parts come out exactly as intended and avoid pitfalls like sink or shrinkage. Our mastery of process control and material behavior allows us to minimize unnecessary post-processing requirements, such as trimming, and deliver high precision parts that meet the strictest tolerances. For necessary post-process treatments like assembly, painting, or fastening, IMS upholds our precision injection molding standards.
To provide customers with a clear understanding of the final product, IMS employs advanced 3D printing technology. Our precision 3D printers produce prototypes that closely resemble the actual model dimensions. This allows customers to visualize and test the part's form, fit, and function before moving into production. In alignment with our goal of customer satisfaction, IMS utilizes the highest quality 3D printers to deliver prototypes with tight dimensional tolerance.
Before proceeding to production, IMS experts conduct thorough tool verification and First Article Inspection (FAI). The toolmaker runs samples and ships them to IMS for evaluation. We measure the tolerances of these samples to ensure that the injection mold can consistently produce precision plastic parts within the given requirements. Once the customer approves the samples, the mold is shipped to our facility for FAI.
During the FAI process, we utilize the Cp/Cpk (Process Capability Analysis) method to assess the precision and consistency of the parts. By running our own sample lot and checking the primary dimensions of each sample injection molded part, we can determine the mold's capability to produce parts that meet the desired specifications. Our target Cp/Cpk value is greater than 1.33, and we are proud that our regular results exceed this threshold, ranging from Cpk 2.5 to 3. This level of consistency assures our customers that each plastic part will be consistently produced with the utmost precision.
Our commitment to precision extends to our production processes. We employ proactive Quality Assurance (QA) techniques to prevent defects and rejections. By identifying potential risks and areas of improvement, we ensure consistent and high-quality production. Our operators perform regular inspections throughout the production run, and we conduct maintenance on molds and injection machines to ensure longevity and precision.
In the event of a defective plastic part, we implement reactive Quality Control (QC) measures. We employ a corrective action process, starting with a corrective action report to contain the issue and prevent further defective parts from being released. Through root cause analysis, we identify the underlying cause of the defect and implement the necessary corrective solutions, such as process adjustments or molding machine operator training. This information is then fed back into our Quality Assurance system to further refine our precision plastic injection molding process and maintain the highest level of dimensional accuracy in each plastic component we manufacture.
In order to maintain the highest standards of quality, IMS utilizes the concept of Acceptable Quality Limits (AQL) based on Mil standard 105D. AQL is a heavily utilized sampling plan across our manufacturing processes. It enables us to conduct Out of Box Audits (OAB's) and statistically assess the quality of finished products. By referring to the AQL chart (see below), we determine the number of parts in a lot that need to be tested to ensure compliance with quality standards. This rigorous sampling plan allows us to identify any potential deviations and take corrective actions promptly, ensuring that our products consistently meet the desired level of precision. By employing AQL, IMS further strengthens our commitment to making parts right the first time and upholding our reputation for delivering precise, high-quality plastic components.
Integrated Molding Solutions understands that precision and consistency require skilled operators who are well-versed in the intricacies of the molding process. To ensure that our team meets the highest standards of expertise, we provide comprehensive training programs for our employees. Through these programs, our operators receive in-depth knowledge about injection molding principles, machine operation, mold maintenance, and quality control procedures. We also offer opportunities for our employees to become certified operators, equipping them with the necessary skills and knowledge to handle complex molding projects with precision and efficiency. By investing in training, certification, and continuing education, we empower our team of industry veterans to deliver exceptional results and uphold the utmost precision in every aspect of our operations.
At Integrated Molding Solutions, precision is at the core of everything we do. From the initial design phase to the production process and quality control, we strive for consistency and accuracy in delivering high quality plastic parts. By employing cutting-edge technologies, adhering to rigorous quality control standards, and leveraging our expertise in material behavior and process control, we ensure that every part meets the required specifications. Partner with IMS for precision injection molding services that meet your needs, and experience the difference that true precision can make in your molded parts and products. Contact us today for additional information.
Which industries do precision plastics have a role in?
Automobile parts
Household appliances
Healthcare and medical devices
Electronics
Telecommunications
Waste Treatment
Like anything that's made, there are degrees of perfection ' and this is also true in manufacturing methods like plastic injection molding. Some plastic products require a high level of detail and precision, as they need to meet exact standards and specifications. This is where services like precision plastic injection molding step in. This helps you build molds within very tight tolerances, and takes into consideration the final application of the part to determine the best approach for manufacturing.
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Let's discuss further the role of precision plastics in different industries to give you a better idea of what this service can do.
Traditionally, automobile parts were made largely from metal. After all, they used to offer the best mechanical and physical properties out of all manufacturing materials.
But, the modern plastic industry has made several advancements when it comes to the kinds of resins we can use in injection molding. And, these resins now offer even more attractive qualities, compared to metals.
Plastics like polypropylene, polyurethane, and polyvinyl chloride are lightweight, affordable, long-lasting, malleable, and corrosion-resistant. These qualities help cars achieve better fuel efficiency and offer designers greater design freedom than metals.
Precision injection molding offers the high degree of precision that is needed for car parts. This method is used to create things like gears, sensors, fuel injection connectors, car multimedia, ECU housings, and more.
Household appliances, too, have demanding requirements that may be difficult for other plastic manufacturing techniques to achieve.
Plastic injection molders use precision molding and engineering resins to create the ergonomic features, low-heat, electrical conductivity, electrical insulation, color-ability, and clarity that many household appliances today need.
The strict sanitation regulations in the healthcare and medical fields mean that specialty plastics are a must for a variety of tools and devices. These plastics are engineered to withstand exposure to harsh cleaners and autoclave devices, on top of being safe for patients and healthcare practitioners to use.
There are several medical-grade plastics that plastic injection molders can use, but these require tight-tolerance machining for dependable accuracy. This is needed to create things like medical device components, laboratory tools and consumables, disposable personal protective equipment, pharmaceutical packaging, and delivery devices.
Things like microelectronics, circuit boards, and electronic housing are often made of plastic.
There are two main requirements for plastic injection molding to meet when it comes to making plastic components for electronics. The first is that the components themselves must fulfill even the smallest details in the design. Second, the plastics and manufacturing process must be tailored precisely to meet the needs of often sensitive electronic parts.
Precision plastic injection molding can meet the demands of electronic equipment. This method can achieve the efficient manufacture of reliable electronic components, which offer a variety of properties that are ideal for this application, such as antistatic or conductive qualities, high heat resistance, high mechanical strength, and more.
The telecommunications industry needs to create a network that is fast, reliable, and can service customers. Many telecommunications companies are also looking to cut downtime, reduce material costs, and create systems with stronger, longer-lasting parts.
And precision plastics help them do just that. Advanced engineering plastics, in particular, are very applicable in this industry. They offer key benefits, such as antistatic and static dissipation properties, extreme resistance to heat and corrosion, and suitability for outdoor applications ' all of which in turn prevent overheating and damage to sensitive circuits. They also are easy to manufacture, which allows companies to produce custom part replacements quickly and avoid costly downtime.
Treatment plants in general are challenging environments to manufacture for, as they often entail exposure to extreme environments, treatment and cleaning products, and the like.
Wastewater treatment plants are included in this. Their environment means that any plastic must be able to withstand constant moisture, as well as severe chemical processing. Luckily, several types of plastic offer low porosity and high chemical resistance, which helps them from becoming corroded, as well as preventing the absorption of contaminants.
Precision plastics and injection molding are the ideal solutions for these facilities. They help create more sanitary and efficient waste treatment processes. Common precision plastic parts in this field include wear pads, seals, rollers, valves, connectors, brushings, drainage units, catch basins, and much more.
Plastic injection molding is a widespread manufacturing method, found in nearly every industry. In general, this method offers versatility and superior properties, which makes them a great choice for a variety of applications.
Under this are precision plastics, which have many roles in the same industries. The role of precision plastics in these fields is often to create better, more reliable products, all while lowering risk and costs for companies.
If you're interested in learning more about precision injection molding, and whether it is a good fit for you and the product you have in mind, contact Richfields. We are a trusted plastic injection molder with years of experience in the precision plastics field ' and we can help you fulfill the product you are thinking of!
Contact us to discuss your requirements of Precision Plastic Mold Parts. Our experienced sales team can help you identify the options that best suit your needs.