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Injection
Molding : |
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For projects with high annual volume
requirements, injection molding is usually the
most advantageous manufacturing approach. In injection
molding, materials are fed into the press in strip
form, warmed and then forced into a mold under
controlled pressure, temperature, and injection
speeds. Tight control on the molding conditions
makes this process productive and accurate, however
tooling costs and set-up times can sometimes be
higher than other production methods. |
Most appropriate
applications
- High Volume Production
- All rubber durometers
- Small to mid-size parts
- Intricate parts
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Process
Advantages
- Consistency
- Faster cycle times
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Ram
Injection : |
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Ram injection is a simplified
version of injection molding, in that materials
are forced into a mold. The difference is the
simplicity of the set-up and delivery of the material.
Billets of material are placed in a cylinder and
then forced into the mold. The product is formed
in the mold and removed when cured. Material runner
is relatively small. This ram injection process
is suited for low to high volume runs. Process
set-up times are lower than Injection molding
– making product changeover much faster.
However, the number of parts than can be produced
per shift is much lower than injection molding. |
Most appropriate
applications
- Low to mid- volume production
- All rubber durometers
- All size parts
- Insert molding
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Process
Advantages
- Rapid mold set-up
- Small amount of runners
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Transfer : |
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Transfer is similar to Ram Injection.
However, in this process a block of material is
placed in a "pot" and then, with a punch, forced
into a mold. The process requires little set-up
and thus is suited to low volume runs. |
Most appropriate
applications
- Low to mid- volume production
- All rubber durometers
- Parts with thick wall sections
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Process
Advantages
- Rapid mold set-up
- Suited to large parts
- Maximize cavity pressure
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Compression : |
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Compression molding of rubber
products is the oldest of the production technologies.
A premixed, and presized mass of rubber is set
into a mold cavity and then squeezed, heated,
and held until cured. The method is simple and
very suitable for certain materials, low to mid-volume
production runs, and especially for larger parts. |
Most appropriate
applications
- Low volume production
- Full range of durometer materials
- Larger parts
- High Cost Materials
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Process
Advantages
- Rapid mold set-up
- Ability to handle high durometer
materials
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Polyurethane Cast Compression: |
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Urethane material can be cast using a compression process. The polymers and curative is premixed and poured into a mold. The mold is overfilled with raw material so that when the mold plates are fit together and placed under pressure, the excess material helps to carry out the air. After parts reach a "green strength", they are demolded and moved to a secondary post cure oven. |
Most appropriate
applications
- Precision components
- Thin walls
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PROCESS ADVANTAGES
- Minimal secondary operation
- Controlled closure tolerances
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Polyurethane Open Cast : |
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Polyurethane products, because
of the liquid nature of the material in its uncured
form, are often produced in an open cast process.
In the process, the polymers and curative agents
are premixed and poured into an open cavity of
a mold. After parts are partially cured, they
are removed from the mold. Parts are exposed to
a secondary post cure in an oven. |
Most appropriate
applications
- Full range of durometers (larger than
rubber)
- Insert molding
- Mid + low volume production runs
- Prototyping
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Process
Advantages
- Rapid changover of materials/color
- Lower cost tooling
- Large size Capabilities
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