OEM Plastic Injection Molding Secondary Molding

Ultra Thick Secondary Injection Molding is a specialized process in the field of injection molding, where high-density and thick parts with complex geometries are produced. This technique involves injecting a large amount of molten plastic material into a mold, which is designed to accommodate the thicker walls and sections of the part being manufactured.

 

The process typically consists of the following steps:

 

1. **Material preparation**: A suitable thermoplastic polymer, such as polycarbonate, polypropylene, or nylon, is prepared and melted to a uniform temperature for injection.

 

2. **Mold design**: The mold is specifically engineered to handle the thick sections. It may consist of multiple cavities or cores to accommodate the larger part dimensions and ensure proper filling and ejection.

 

3. **Injection**: The molten plastic is injected into the mold under high pressure, filling the cavities and creating the desired shape. Special attention must be given to the fill pattern and cooling channels to prevent defects like warping or shrinkage.

 

4. **Cooling and solidification**: After the plastic has been injected, it is cooled rapidly to minimize shrinkage and improve dimensional accuracy. Large parts may require additional cooling systems or extended cooling times.

 

5. **Ejection**: Once the part has cooled and solidified, it is carefully ejected from the mold using mechanical actuators.

 

6. **Post-processing**: Any post-molding operations, such as trimming, deburring, or surface finishing, are performed to clean and refine the part.

 

Ultra Thick Secondary Injection Molding is commonly used for applications that demand high strength, durability, or structural integrity, such as automotive components (like bumpers or door panels), packaging materials (thick-walled containers), and industrial machinery parts. However, due to the increased material usage and potential for challenges in achieving uniformity, this process can be more expensive than standard injection molding techniques.