Insert Injection Molding Supplier In China
Maximize Your Savings with a Trusted Insert Injection Molding Partner
China Plastic Insert Molding Expert
Stebro Mold is a full service custom insert molding supplier in China. We use the vertical Engel injection molding machine to produce high-quality insert-molded plastic components. You won’t have to contact multiple mold manufacturers and injection molding companies when you work with us. You can have the advantage of a single-source plastics provider from idea to shelf.
Our services include:
- 2D & 3D product design and optimization
- The material selection
- Rapid prototyping services
- Cost-effective insert mold solution
- Mold Flow Analysis to optimize the mold design
- In-house insert mold manufacturing, mold change, mold trial, tooling transfer and maintenance
- Pre-production runs and mass production
We’re here to make sure your projects are a success! With our help, you’ll get insert molded parts done correctly from the start, within your budget, and on time.
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Why Stebro Mold for vertical injection molder
What is vertical injection molding?
vertical injection molding is a specialized manufacturing process used to create intricate plastic parts by injecting molten plastic material into a mold cavity using a vertically oriented injection unit. This process is widely employed in various industries due to its precision, efficiency, and ability to produce complex components with tight tolerances.
Vertical injection molding machines have a vertical clamping unit, which holds the two halves of the mold (core and cavity) together during the injection process. This vertical orientation offers several advantages, such as improved precision, reduced footprint, and easier integration with automated systems for insert molding, overmolding, and multi-component molding.
Vertical Injection Molding Process
- Material Preparation: The process begins with the selection of an appropriate plastic material, typically in the form of pellets or granules. The chosen material should meet the specific requirements of the application, such as mechanical strength, durability, and resistance to environmental factors.
- Material Feeding: The plastic pellets are loaded into the machine’s hopper, which serves as a storage unit. The pellets are then transported to the injection barrel through a rotating screw.
- Plastic Melting: Inside the barrel, the plastic pellets are heated using external heaters and friction generated by the screw’s rotation. This process melts the plastic material, turning it into a viscous state suitable for injection into the mold cavity.
- Injection: As the screw moves forward, the molten plastic is forced through the nozzle at the end of the barrel and into the mold cavity. The vertical orientation of the injection unit ensures precise control over the flow of material and accurate placement within the mold.
- Cooling and Solidification: Once inside the mold, the plastic material begins to cool and solidify, taking on the shape defined by the mold cavity. The cooling time depends on various factors such as the material, part thickness, and mold design. During this phase, the plastic part undergoes shrinkage, which must be accounted for during mold design to ensure dimensional accuracy.
- Mold Opening and Part Ejection: After the cooling phase, the clamping unit releases pressure and opens the mold, separating the mold halves. The finished part is then ejected from the mold cavity using a variety of methods, such as ejector pins, stripper plates, or air blasts. In some cases, robotic arms or other automation systems are used to remove the part and place it onto a conveyor or other transport system.
- Mold Closing and Clamping: Once the part is ejected, the mold closes again, and the clamping unit applies pressure to hold the mold halves securely together. This prepares the mold for the next injection cycle.
- Cycle Repetition: The entire process is repeated for each cycle, allowing for continuous production of identical plastic parts. The cycle time is determined by various factors, such as injection pressure, temperature settings, cooling time, and material properties.
- Quality Control and Inspection: Throughout the production process, quality control measures are implemented to ensure consistent part quality and minimize defects. This may include visual inspection, dimensional measurements, and testing of mechanical properties.
- Post-Processing: Depending on the part requirements, additional post-processing steps may be necessary, such as trimming, deburring, or painting. Some parts may also require assembly with other components before being shipped to customers.
Vertical Injection Moulding Advantages
- Space Efficiency: Smaller footprint than horizontal machines.
- Insert Molding and Overmolding: Easier integration of automated systems.
- Enhanced Precision: Improved part quality and reduced defects.
- Faster Cycle Times: Increased production efficiency.
- Gravity-Assisted Flow: Reduced occurrence of flow marks and sink marks.
- Ease of Automation: Simplified integration with robotic systems.
- Multi-station Configurations: Simultaneous production of different components.
- Improved Ergonomics: Comfortable working height for operators.
Vertical Injection Moulding Disadvantages
- Limited Clamping Force: Lower force compared to horizontal machines.
- Mold Accessibility: Challenging mold maintenance and cleaning.
- Part Size Restrictions: Unsuitable for larger or complex parts.
- Cost: Higher expense compared to horizontal machines.
- Lower Throughput: Reduced production rate in some cases.
- Limited Material Options: Incompatibility with certain materials.
Vertical Injection Molding Machine
- Single-Station: These machines have a single clamping unit and are designed for low to medium-volume production. They are ideal for small components and straightforward applications.
- Multi-Station: Multi-station vertical injection molding machines feature multiple clamping units, allowing for simultaneous production of multiple parts or components. These machines are suitable for high-volume applications or when manufacturing different components in one cycle.
- Rotary Table: These machines have a rotating platen that moves the mold between the injection and cooling stations. This design enables continuous production and shorter cycle times, as the injection and cooling processes occur simultaneously.
- Shuttle Table: In a shuttle table configuration, two or more molds are mounted on a horizontal table that shuttles between the injection and cooling stations. This setup allows for continuous production and minimizes downtime between cycles.
- Two-Shot or Multi-Shot: These machines are designed to produce parts with multiple materials or colors in a single cycle. They feature two or more injection units that can inject different materials into the same mold, creating complex components with reduced assembly requirements.