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With every new decade comes a new technological revolution that helps us advance to the new age of technological mastery and innovation, from the Stone Age to the Copper Age, to industrialization and to now where we are moving towards the age of efficient and long-lasting technology, this means the production process needs to be efficient. The product developed from the process must be efficient and sturdy to ensure long-lasting.
As we are into the age of plastics, we have to take necessary steps to make sure that plastic is helpful and not harmful to us and our planet, one way of making this possible is to use bioplastics and another is to make sure that the components are made with high-quality components and designed in such a way that they last a long time and to reduce their impact on this green and blue globe of life, and here is where the technology of insert moulding process helps, the process of insert moulding is where the plastic components are fused with other materials or metals to make their strength much higher than normal plastic components, and life much longer than normal injection moulded components while also reducing production time of these components making the production process much more efficient and cost-effective.
Insert moulding is the process of fusing plastics with other materials or metallic inserts, such that the core components known as inserts are to be placed inside the mould cavity and plastic is moulded around the insert fusing both the parts into a single object which has increased strength due to the core insert and higher protection and life due to the bonding of plastic via insert moulding process, some examples of insert moulding process are, Surgical components, Electrical components (cables, sensors, circuits, etc), Automobile components(Keys, bumpers, hinges, connectors, dashboards, etc), household components(knives, scissors, glasses, bowls, pens, etc), industrial components( impalers, fans, bearing cages, valves, fittings, etc).
Vertical injection moulding machines are developed and designed with components and the process of insert moulding in mind, these machines are highly efficient when it comes to the insert moulding process, due to their construction and operational sequence it becomes very easy for the operator to place inserts inside the mould and also the probability of that insert moving from its position is next to zero, which makes the process of insert moulding very predictable and safe on vertical injection moulding machines.
Some advantages of vertical injection moulding machines are mentioned below.
Optimized for Overmoulding
Vertical injection moulding machines excel in overmoulding, a process where one material is moulded over another. Whether it's creating multi-material products or inserting metal components into plastic, vertical machines offer better control and accuracy, ensuring perfect alignment every time. As the mould opens vertically the inserts are placed onto the mould cavity, just like placing something on a flat surface, thus making the insert more secure and less likely to move from its place.
Space-Saving Design
Due to their vertical configuration, vertical injection moulding machines take up less floor space compared to their horizontal counterparts. This space-saving design allows manufacturers to fit more machines in the same area, boosting productivity without the need for large factory floors.
Ease of Insert Moulding
Insert moulding, where metal or other materials are placed into the mould before the plastic is injected, is another area where vertical injection moulding machines shine. The vertical clamping design simplifies the process, making it easier to load inserts manually or using automation. This results in enhanced production efficiency and reduced labour costs.
Precision and Repeatability
Vertical injection moulding machines offer exceptional precision, making them ideal for manufacturing small and intricate components, such as medical devices or electronic parts. The clamping mechanism ensures consistent pressure and alignment, leading to higher quality and repeatability, even for complex designs.
Enhanced Operator Accessibility
Operators benefit from easier access to the mould area. Since the mould opens vertically, and there are no physical doors between the operator and the mould working area, it’s simpler to load materials or remove finished products, improving workflow and reducing downtime during production cycles.
High Level of Safety
As the mould clamping area is open, there are multiple safety devices built into the machine to make sure that the operator is safe from the machine no matter what, in the case of multi-station vertical injection moulding machines the mould is slide/rotated out of the clamping area where the operator works on the mould to load inserts and unload components, making sure that the operator is never near danger while operating the machine at its full capacity.
Very High Operational Efficiency
With the help of multiple station vertical injection moulding machines, an operator can keep working on the moulds (loading inserts and unloading finished moulded components), while the machine continues its moulding operations at another station and as soon as both the machine and operator finish their work the moulds switch stations and the machine keeps on working without wasting any time, increasing the output efficiency of the machine by many times.
High Level of Customization
Vertical injection moulding machines offer a high level of customization which means you can have a machine that is customized in such a way that it offers the perfect solution for your production requirements, be it injection customization, clamping customizations, automation customizations, access customizations, vertical injection moulding machines have multiple models and all these models can be further customized to make sure they suit your production requirements the best.
As the industry is moving onwards with components and products that require insert moulding(over moulding) for them to be manufactured, the only logical way to manufacture them is by using a vertical injection moulding machine, and these machines are the more idealistic choice for insert moulding of the components.
Explore the full range of vertical injection moulding machines
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