This is a thin wall plastic injection moulding fast food packing container for Asia market. The wall thickness is just 0.45 mm with food grade PP material. There are 2 sets 4 cavities mold. One mod is for base container and another one is for cover.
Thinwall plastic injection moulding
Core surface finish:
PP food grade
Cavity surface finish:
No of Cavities:
8407 with heat treatment to 48 to 52 HRC
Type of gating:
Hot runner point gate
8407 with heat treatment to 49 to 52 HRC
Slider and lifter material:
Lead time for T1
Mold base steel:
3 000 000
Place of Origin
Mold size :
600 x 800 x 450 mm
1) PP food grade thin wall plastic injection molding for container and pack
2) 8.5 seconds fast cycle time with super long mold span life up to 3 millions
3) Full hot runner , no material wastage in the mass production
4) Full automatic production running by robot
5) Export mold to customer side , Asia Billion only make the mold and when the mold is approved ok
6) Fast lead time , it is just 40 day from the PO to mold shipment to customer plant.
Asia Billion is a high quality thin wall plastic injection moulding company and injection mold maker. If you need to know more about us , please contact us freely.
What is a thin wall ?
A simple viewing is called thin wall when the wall thickness is less than 1 mm. More comprehensively, the definition of thin wall is related to the process/wall thickness ratio, the viscosity of the plastic, and the heat transfer coefficient. The process L from the main flow path of the mold to the farthest point of the finished product, divided by the wall thickness t of the finished product, is called the process/wall thickness ratio. When L/t>150, it is called thin wall. If the thickness of the process is inconsistent, it can be calculated in stages. The flow/wall thickness ratio PP has a viscosity factor of 1. The disposable lunch box has a flow of 135 mm, a wall thickness of 0.45 mm, and a flow/wall thickness ratio of 300. The viscosity factor of the PC is 2. The flow of the mobile phone battery case is 38 mm, t = 0.25 mm, and the flow/wall thickness ratio = 152. Multiply the viscosity factor by 304, which is similar to the lunch box.
Why we need thin wall plastic injection molding?
The cost of plastic raw materials usually accounts for a large proportion of the cost of the product, such as 50-80%. Thin walls help to reduce this ratio. Due to the miniaturization and portability of consumer electronic devices such as mobile phones, MP3 players, digital cameras, and handheld computers, the related plastic parts are becoming thinner and thinner. Thin walling has become a new research hotspot in the plastic injection molding industry due to its advantages of reducing product weight and external dimensions, facilitating integrated design and assembly, shortening production cycle, saving materials and reducing cost. The design ideas and methods of thin-walled products are more complicated and further affected by molding limitations and material selection. Thin-walled products are required to have high impact strength, good appearance quality and dimensional stability, and can withstand large static loads, and the flowability of the molding material is good. The design process should focus on the rigidity, impact resistance and manufacturability of the product. Specially designed thin-walled products are specially designed for forming thin-walled products.
Compared to standardized molds for conventional articles, injection molds for thin-walled articles have undergone major changes from mold structures, gating systems, cooling systems, exhaust systems, and demolding systems. Mainly in the following aspects:
(1) Mold structure: In order to withstand the high pressure during molding, the thin-wall molding die has a large rigidity and a high strength. Therefore, the moving and fixed stencils of the mold and the supporting plate are relatively heavy, and the thickness is usually thicker than that of the conventional mold. There are many support columns, and there may be more internal locking in the mold to ensure accurate positioning and good side support to prevent bending and offset. In addition, the high-speed injection speed increases the wear of the mold, so the mold should use higher hardness tool steel, the hardness of high wear and high erosion areas (such as the gate) should be greater than HRC55.
(2) Gating system: Forming thin-walled products, especially when the thickness of the product is very small, a large gate is used, and the gate should be larger than the wall thickness. If it is a sprue, a cold well should be installed to reduce the gate stress, assist the filling, and reduce the damage when the product is removed from the gate. To ensure that there is sufficient pressure to fill the thin cavity, the pressure drop should be minimized in the runner system. For this reason, the flow path design is larger than the conventional one, and at the same time, the residence time of the melt is limited to prevent degradation of the resin degradation. When it is a multi-cavity, the balance of the casting system is much higher than that of conventional molds. It is worth noting that two advanced technologies, hot runner technology and sequential valve gate (SVG) technology, have also been introduced into the casting system for thin-walled product molds.
(3) Cooling system: Thin-walled products can not withstand the large residual stress caused by uneven heat transfer like traditional thick-walled parts. In order to ensure the dimensional stability of the product, and to control the shrinkage and warpage within an acceptable range, it is necessary to strengthen the cooling of the mold to ensure the cooling balance. Good cooling measures include the use of non-closed cooling lines in the core and cavity modules, increasing the cooling length, and enhancing the cooling effect. High-conductivity metal inserts are added where necessary to accelerate heat transfer.
(4) Venting system: Thin-wall plastic injection molding tools generally need to have good venting properties, and it is best to perform vacuuming operations. Due to the short filling time and high injection speed, it is very important to fully exhaust the mold, especially the exhaust in the flow front gathering area, to prevent trapping of the gas. Gas is usually discharged through cores, rams, ribs, studs, and parting surfaces. The end of the flow channel should also be fully exhausted
5) De-moulding system: Because the walls and ribs of thin wall plastic injection moulding part thickness are very thin, they are very easy to damage, and the shrinkage in the thickness direction is small, so that the ribs and other small structures are easily bonded, and the high pressure holding pressure makes the shrinkage smaller. . To avoid topping and sticking, thin-wall injection molding should use a larger number of ejector parts than conventional injection molding.