3d molding of plastic
3d molding of plastic. You have the desire to make products from plastic, and we have – the ability to do it qualitatively. Let’s start with the main thing. What factors will depend on .The manufacturing process is determined by the product edition. For example, when pressurized plastic molding is made expensive metal mold. This increases the cost of the initial stage. However, the more product produced with its help lower the cost of the product becomes.
Product material. For each project selected thermoplastic resins with optimal performance and reasonable price. Dimensions of the finished product. The size of the product affects the amount of material, as well as the cost of preparatory work. The complexity of the product geometry. The more complex the product, the higher the cost of the work.
METHODS FOR PRODUCTION OF PLASTIC
There are 3 ways to manufacture plastic products depending on circulation:
First and foremost when choosing a method of manufacture of plastics experts “clones” of the company are guided by your terms of reference, and then – to the circulation.
One of the most common methods of 3D-printing – simulation by fusing layering on the printer FDM ( Fused Deposition Modeling). Technology FDM involves the production of three-dimensional objects using layers of thermoplastics. Used for prototyping and small batch production.
Other common methods of 3D printing:
Stereolithography (SLA-printing) – manufacture of plastic articles from liquid photopolymer resin. The solidification of the resin occurs due to irradiation with ultraviolet light. This method is more expensive FDM-print, but it is 7 times more accurate.
Selective laser sintering (SLS-printing) – a method of sintering the powder material layers using high power lasers.
Plastics molding in the form of silicone provides for the casting of parts in vacuum and allows you to get an exact copy of the original object. Silicone molds used in small-scale production.
Injection molding under pressure takes place by injecting molten resin into a metal mold followed by cooling. Casting method is used for large-scale production.
Comparable methods on the example of one product. We calculated the cost of production of various methods of plastic housing with dimensions of 165 mm 95 mm X 75 mm.
STAGES PRODUCTION OF PLASTIC
Casting plastic in the silicone mold, and the mold begins to design 3D-model of the product in the product range CAD-programs (SolidWorks, AutoCAD, FreeCAD).
If future product has no analogues and precursors, 3D-model is developed based solely on the technical specification requirements.
If the product is not unique, the design used references of – reference samples of the product.
After creating a 3D-model in a digital form, go to the production of prototypes. It will help to assess the functionality of the developed products. In steps prototyping design changes do not entail significant costs.
The product of the of 3D-printers has a layered surface. If the customer meets this type of quality – the rest of the modest print run is printed on the printer and passes the grinding procedure.
If the requirements are higher, or need to get a larger volume of production output – use the techniques of molding of plastic into molds. We consider separately the small-scale and large-scale production.
SMALL SCALE PRODUCTION: INJECTION MOLDING IN SILICONE
In small-scale production use injection molding in a silicone mold . To create a master model prototype printed the 3D-printer, treated with varnish and skins to produce a smooth surface.
Master model is half immersed in a clay basis and pour a mixture of silicone and a hardener. Mold poured left for 24 hours in a chamber for degassing and solidification.
The result is half silicone molds.
Then, repeat the process and get the other half. We connect the two elements form, using the frame for rigidity. Fill silicone polyurethane form, subject to the camera.
Depending on the type of plastic solidification time is from 4 to 24 hours.
LARGE-SCALE PRODUCTION: MOLDING OF PLASTIC UNDER PRESSURE
When large-scale production of the most resource-intensive phase – manufacturing molds of metal. Molds are durable and make it possible to obtain products with high accuracy of detail.
Drawing. The metal mold for molding plastic.
In the process of molding plastic is fed into the injection molding machine, where they are melted, homogenized and injected under high pressure into the mold. First, the material hardens near the cold wall, then – casting within the body.
After cooling, the mold is opened, the product proceeds to final processing step, and form – for a new casting cycle. Ends final cycle of work piece: sprue cutting, routing, application soft-touch covering.
REVIEW OF MATERIALS FOR THE CASTING OF PLASTICS
Consider the types of materials that are used for casting.
For ZD-printing, are generally used thermoplastics and composite materials on their basis. The most popular types: polylactide, polyvinyl alcohol, nylon, metal imitators.
For casting in silicone mold used polyurethanes which can withstand temperatures of -60 ° C to +80 ° C.
Injection molding can be used with a wide range of materials: from conventional polyurethanes to polycarbonates.
Now that you know the theory, but have no idea how to put it into practice – take a deep breath and enter the number of “clones”. We’ll help you. With pleasure.