Injection moulding is used to make various products, including but not limited to insulators, dashboards, battery casings, and decorative fixtures. Plastic components are used in many industries, ranging from automotive to home appliances and medical devices. Despite the fact that injection moulding demands large machines and a greater volume of plastic resins, it’s a fantastic choice for high-volume production owing to the relatively short cycle time. Structural foam moulding is often used for applications that require high-end aesthetics and rigid yet lightweight properties. A blowing agent creates a cellular structure while a firm skin forms. The outcome is a product that requires fewer post-production processes (and less assembly).
Automation is an important yet necessary step as far as injection moulding large plastic products is concerned. Not only can it increase production capabilities and overall efficiency over the years, but it can also reduce the need for manual labour and minimise the risk of human error. Many plastic goods are susceptible to contamination via human interaction, which translates into the fact that automation is of the essence for anyone working within the medical or electronic field. By automating the injection moulding process, you guarantee the same amount of material is introduced into the mould each time at the same pressure.
A Quick Overview of Automation in Plastic Injection Moulding
Automation is achieved by leveraging programmable devices, systems, and tools, of which mention can be made of artificial intelligence, robots, and computer-controlled machines. It decreases limits on what a company can achieve, automated tools almost always working faster and occupying less floor space. Robotic systems accommodate sophisticated sensors and actuators, not to mention they have programming capabilities that allow for the accurate and methodical execution of tasks. Figuring out how to best implement automation in the plastic injection moulding process is challenging, as there are several factors to consider. More precisely, you must determine if your employees have the necessary skills for the future of work and see how automation would fit within your workspace.
Common uses for automated processes are:
Material handling
Mould setup
Part ejection
Quality control
Packaging
Many agree that the future of plastic injection moulding belongs to automation. In other words, it’s expected that the advancements in the field will bring about considerable benefits. Plastic components are needed for parts from the simplest to the most complex, and no manufacturing method can rival injection moulding. As we all know, one of the most popular types of injection moulding is structural foam moulding, which achieves the exact design and performance requirements.
Automation Can Enhance the Moulding Process by Allowing
Enhanced Efficiency
Those involved in manufacturing consider costs unavoidable expenses, even if it’s possible to get a grip on spending. Automation enables manufacturers to reduce labour costs by eliminating manual handling and repetitive tasks, which leads to enhanced efficiency in injection moulding projects. It can be used right at the injection press to gain control over the plastic parts, so it’s not necessary to transport the goods to and from the warehouse for processing. Streamlined processes mean faster production cycle times, which are the lifeblood of increased productivity. Meeting customer demands signifies that sales are maximised, and delays in the supply chain are minimised.
Consistent Quality
Thermoplastic composites permit manufacturers to produce high volumes with consistent quality. Tight tolerances, accurate dimensions, and adequate material flow are of the essence when it comes down to attaining the desired functionality. Using automated tools vastly improves and streamlines the development process, as the equipment follows the programmed instructions precisely. An injection moulding machine will run the same every time, so companies can provide the same level of service on a regular basis. The default expectation for end customers is that the plastic parts have consistent dimensions and features across each unit – interchangeable components are provided from batch to batch.
Cost Savings
As mentioned earlier, some manufacturers fool themselves into thinking that overheads are inevitable. What they don’t know is that, by implementing automation, companies can seize several cost-saving opportunities, such as reducing labour costs. Designing, creating, and assembling injection moulds is an undertaking that requires a large workforce consisting of highly trained specialists. Since every production cycle uses the exact amount of plastic needed to fill the mould, injection moulding involves almost no waste, meaning that automation contributes to optimal material usage. Automated tools can remove the leftover solid material from different parts.
Increased Flexibility
Finally, yet importantly, automation increases flexibility (and sustainability) in injection moulding by enabling manufacturers to make a wider range of products with a given investment capital. Many scenarios prompt a switch between moulds and part designs, so it’s necessary to manage expectations right away to stabilise the supply chain. Real-time monitoring of the injection moulding process allows for predictive maintenance, one of the main topics of Industry 4.0. Data analysis is used to identify anomalies in the operation and possible defects in equipment or processes so it’s possible to solve problems before they occur. Minimised deviations ensure optimal performance.
Conclusion
To conclude, plastic development, advances in machinery, and customer demands will influence the future of injection moulding. While it’s impossible to predict exactly what will happen in the future, there are prevailing tendencies that will shape the course of the following decade. Automation has been part of injection moulding for some time now, yet the pace of innovation is accelerating, and competitive pressure is increasing. As technology continues to evolve, an ever-increasing number of tasks will be automated; the benefits are immediate for manufacturers seeking a competitive edge. Injection moulding can be used to make all parts needed for a product.
Regardless if the outcome is simple and straightforward or complex and demanding, plastic injection moulding brings about numerous advantages in today’s manufacturing environment. If you rush into automation without a clear purpose, you won’t obtain the expected results, so consider the robot type, end-of-arm tooling, and plan for testing. In other words, you don’t want to rush into it. Automation in plastic injection moulding is neither overstated nor exaggerated.
