Injection Moulding

Blow Moulding

Blow Moulded Tank

Film Application

Pale Container Application

Extrusion Application

Woven Sack Application

Injection Moulding Applications

We Provides all types of injection moulded products solutions like cost, quality & properties etc. Bajaj also provides high efficiency and fast production, Injection Molding can handle extremely complex parts and uniformity. It helps to enhance the strength of the product, Flexibility of production is endless because of the wide range of material and color. It reduced waste and low labor costs. Bajaj Masterbatch provides customized products as per customer requirements.

NEED FOR INJECTION MOULDING

Wide Variety

This is most common plastic processing technique used for manufacturing a wide variety of plastic items ranging from smallest components like Caps, buttons, Electrical & Electronic parts, buttons, etc to large components like Car bumper , dash board, Home Appliances body , etc.

high production output

The process itself is extremely fast compared to other methods, and the high production output rate makes it even more efficient and cost-effective. Speed depends on the complexity and size of the mold but only about 15-120 seconds pass between each cycle time.

Strength

Strength is one of the key factors determined when designing a plastic injection molded part. The designer will ascertain if the part needs to be flexible or rigid based on it’s end application requirements .

High Quality and Sustainability

When looking for a high-volume injection molding process, it’s important to consider companies’ green manufacturing initiatives, as these signify a commitment to quality, sustainability, and optimal safety.

Lower Labour Cost

Labor costs are relatively low in plastic injection molding, in comparison with other types of molding. The ability to produce the parts at a very high level with a high output rate helps with its cost efficiency and effectiveness.

TYPES OF INJECTION MOULDING

Thin wall moulding

It is a technology that achieves a plastic part with a very thin wall. It is often used in test apparatuses, electronic items, Food containers , tubes, and other enclosures.

Gas assisted Injection molding

is used when any thick plastic injection-molded part is that it runs the risk of distortion as it cools. This method helps to solve this issue by shooting gas into a plastic material-filled injection mold, allows the plastic on the outside of the mold to maintain a smooth and finished appearance while the inside stays porous or hollow.

Micro Injection moulding

is a process of obtaining micro injection moulded parts that weighs less than 1/10th of a gram, here very high precision is involved in both tooling as well as production.

Injection compression Moulding

is a technique where the molten polymer is injected into a partially open mould , then the mould closes to compresses and distributes the melt through out the cavity , completing filling and packing stage. This process works on lower injection pressure providing lower moulded in stress and thin walled part production.

Co-Injection(Sandwich) Moulding

is a process in which 2 different but compatible polymer melts are injected sequentially into a cold mould , forming a skin / core structure . The possibility of using recycled material in the core can be regarded as one of the key advantage in this process.

Insert Moulding process

are mostly done in vertical injection machines with vertical / horizontal clamp unit. In this an insert is placed into the mould cavity before closing and the plastic is then injected around the insert so that the insert becomes a part of the final moulded product.

Foam Moulding Process

is a low pressure process inwhich an inert gas is introduced into molten polymer the purpose of reducing density and hence weight of the finished product. Moulded products have cellular cores surrounded by rigid, integral skins. Foaming agents such as Nitrogen, Carbon di oxide is introduced into the polymer melt stream, creating a homogenous mixture of polymer & gas.

Fusible core Injection moulding

is a specialized process used to manufacture components with cavities / undercuts .

Rapid Injection moulding

is a process to make prototype injection moulded parts in a thermoplastic resin in 2-5 weeks. These parts are used for full functional and fit testing.

2-Shot Injection Moulding

is a technology of producing a part with 2 different raw materials or colours in single operation.

Classification of Injections Moulding

Hand Moulding Machine

It’s a conventional process operated manually , it consists of barrel , plunger, band heaters along with energy regulator, rack & pinion system for Injecting the material by the plunger, through nozzle. This method is highly labour intensive, not popular any more but still used for low volume & small sized Industrial & Household items where aesthetics are not so important.

Vertical & Horizonatal type Injection Moulding Machine

It’s based on its injection unit whether it’s vertical or horizontal.
Injection unit comprises of assembly from hopper till nozzle as seen in picture given above. It’s function is to heat & convey the plastic material from hopper through screw rotating and barrel heating to melt it and inject into the mould. Here, the hot melt enters the mould from its side in line with the injection unit. Those machines having injection unit horizontal or in line with clamping unit are referred as Horizontal Injection moulding machines . If the Injection unit is vertically placed above the mould then it’s referred as Vertical Injection moulding machine wherein the mould is placed below Injection unit & molten material enters into the mould from top.

Advantages of Using
Bajaj Injection Moulding Solutions

Complex Part Design

High Efficiency- Fast Production

Enhanced Strength

Flexibility- Material and Color

Reduced Waste

Low Labor Costs

Further Injection of material can be done by two ways as given below :

1. The Screw type Injection Moulding

The Screw type injection moulding machine which utilizes motorized screw to mix and push the molten plastic material inside the mould. Screw does dual function of melting (compresses , melt and convey) & pushing the material , hence called as reciprocating screw.

2. The Ram type injection moulding

The Ram type injection moulding machine which uses a hydraulically operated plunger to push the molten plastic material into the mould.

Clamping unit

They are placed at the back of the mould in the machine. Mould is clamped to platen of the machine. One platen is stationery which has injection unit at its back while the other one attached to clamping unit is movable. The main function of clamping unit is to keep mould closed when hot plastic material is injected into mould at high speed & pressures. In general, Clamping pressure has to be higher than the Injection pressure. There are 2 types of clamping units, namely

A) Direct Locking unit which utilize a high pressure hydraulic cylinder where clamping forces is focused in the centre providing even force distribution.

B) Toggle clamps which are mechanical clamping providing both high speed and high force at different points in the cycle when required.

Clamping Tonnage : Clamping unit is rated in terms of Tonnage which is the maximum force that the machine can provide to keep the mould closed during the mould process.

Clamping force = Projected Area X Injection Pressure

The projected area of the part can be found based on the geometry ( dimensions) of the part. The injection pressure varies with the flow or viscosity of the polymeric material. Too low a clamping force can lead a short part or unfilled parts while too high clamping force can open mould leading to flash or even damage mould sometimes.

Injection Moulding Process Cycle

Product Solutions for Injection Moulding

Injection Moulding Applications for
Color Masterbatch

Injection Moulding Applications for
White Masterbatches

Injection Moulding Applications for
Black Masterbatch

Injection Moulding Applications for
Transparent Masterbatch

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