INJECTION MOULDING
Ever wondered how the world around you becomes filled with countless plastic parts, from intricate gear components to your favorite phone case?
Injection Moulding
We love baking! We have a high-tech bakery for it. But wait, our dough is different. Because it’s not dough at all. It’s molten plastic. In addition to plastic, ABC, polycarbonate, nylon, and many more, our pantry has bags of ingredients that you possibly look for. The varied kinds of injection moulding capabilities, from thermoplastic, insert molding, over molding, multi-shot, and whatnot, are capable of shaping these materials to the desired dimensions of your imaginations. The quality and precision are never at stake. We just bring life to the drawings that you provide.
At VIA INDIGOS, plastic injection moulding is our mastery, making our final products apt for various industries from oil and gas to paper. We are all set. Moreover, the inspection processes through which they pass just can’t leave a dent behind. From every nook and corner, we make sure that your product turns out to be perfect! Our Partner’s state-of-the-art injection moulding machine and plastic injection molding machine ensure top-notch custom injection molding and custom plastic molding. As one of the leading injection mold manufacturers, our injection molding services guarantee a flawless process.
What is Injection Moulding Process?
Injection moulding process is a manufacturing technique used to produce parts by injecting molten material into a mould. The process involves melting raw material and injecting it into a mould, where it cools and hardens to the shape of the mould cavity.
Types of Plastic Moulding
Via-Indigo can mould any commercially available thermoplastic including engineering plastics and high-performance plastics. Please contact us with your specific resin requirements. Some of the common moulding materials we handled are,
- Heat Staking
- Laser Engraving
- Pad Printing, Painting
- Painting
- Laser Engraving
- Ultrasonic Plastic Welding
- Heat Staking
- Pad Printing, Painting
Quality Assurance – Injection Moulding Inspection Process
To ensure the quality standard of the plastic products we make, at Via Indigo we are implementing the following inspection process and quality control procedures during various stages of production
Appearance Inspection focuses primarily on the surface quality of the product. This includes checking whether the color of the product is consistent, whether the glossiness meets the required standards, and whether the surface is smooth and free from flaws.
During the appearance inspection process of products, manual visual inspection is commonly used. When there is a high volume of production, to ensure accuracy and improve efficiency, camera systems combined with artificial intelligence technology are employed for inspection.
DFM and Mold Flow Analysis
Before the production of molds, it is essential to study and confirm the maturity of product design and mold design. It is crucial to identify potential injection molding defects and strategize ways to minimize their risks.
In-Process Inspection
During the production process of plastic products, the primary areas of inspection are Appearance and Dimensional accuracy.
Material testing
Sometimes, before producing plastic products, performance testing of materials is needed to ensure they meet the requirements and that their calibration parameters are accurate.
In-Process Inspection
During the production process of plastic products, the primary areas of inspection are Appearance and Dimensional accuracy.
| S No | Defect Type | Description | Possible Causes |
|---|---|---|---|
| 1 | Flash | Excess material that escapes the mold cavity, creating a thin protrusion along the parting line | Excessive injection pressure, worn mold parts, or improper clamping force |
| 2 | Sinkage | Depressions or dimples on the surface of the part. | Insufficient cooling time, thick sections, or low packing pressure. |
| 3 | Warpage | Distortion that causes parts to bend or twist | Uneven cooling, improper mold design, or incorrect material selection |
| 4 | Weld Line | Surface defect in which the weld, or the part where the flows of melted plastic meet inside the mould, shows up on the surface as a groove or pattern | Low temperature or fluidity of melted plastic during injection moulding. Insufficient injection pressure and speed can cause weld lines |
| 5 | Flow Line | Visible lines or patterns on the part surface indicating the flow of the molten material. | Variations in material flow, inconsistent cooling, or abrupt changes in wall thickness |
| 6 | Cracking and Crazing | Surface defect where cracks and crazing (fine cracks and lines) occur | External or Internal stress |
| 7 | Voids | Internal or external empty spaces within the part | Gas bubbles, insufficient packing pressure, or rapid cooling. |
| 8 | Burn Marks | Discoloration or burn spots on the part surface. | Excessive injection speed, trapped air, or overheating of the material |
- Contact Measurement involves tools such as calipers, micrometers, and coordinate measuring machines (CMMs).
- Non-Contact Measurement utilizes tools like projectors, image measuring instruments, and scanners, measuring products optically or electronically.
Special Inspection:- Depending upon the customer need we can also perform Destructive Testing and Non-Destructive Testing as well
VIRE
VIA INDIGOS reverse engineering offers you with the ability to deconstruct, reconstruct and re-analyze your entire injection molding process. Moreover, if you can’t get your hands on your complete drawings or operational sheets, our experts are always there for you. We ensure to take full responsibility for your injection molding process. And, make it thoroughly optimized & well documented.FAIR & PPAP
Moving ahead, come First Article Inspection Process (FAIR) and Production Part Approval Process (PPAP), part of VIA INDIGOS Quality Inspection Process VIQIP. In this process, once we’ve mapped out all your operations, our attention shifts to ensuring unparalleled quality. We are aware that in the injection molding services, two factor viz. precision and adherence to quality standards are critical. Therefore, to abide by that we help you meet every benchmark, guaranteeing that your products meet stringent certification requirements.VIMI
Don’t you think managing materials for plastic injection molding is a real challenge? We definitely feel for you. So we decided to take up the challenge head on! VIA INDIGOS Managed Inventory solutions makes sure that this burden isn’t hampering you much. Wondering how? With our cutting-edge warehousing services, it ensures your inventory is safe and that you always have the right amount of stock when needed.VITLM
VIA INDIGOS Tool Life Management system is the one that handles the maintenance and optimization of your injection molding tools. The comprehensive system is crafted in such a ways that it improves tool efficiency extending their lifespan. It holds the functionality to monitor tool wear and tear, provide regular notifications for maintenance, so that your operations run smoothly that to without interruption.
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