Technical information

The plastic injection machine is basically a closed mold after the plastic material is rapidly injected into the mold chamber from the runner inlet at high speed in a temperature range above the melt temperature, and after bringing the size and visual tolerances of the part to an acceptable level with the ironing phase and holding phase, the temperature of the plastic exiting the mold is adjusted. It is a plastic part manufacturing method based on the principle of removing it from the mold by bringing it under the mold. Since it is suitable for mass production, it is a production method that is widely used in many sectors. With this method, plastic parts in a wide variety of sizes and categories can be manufactured, from the smallest components to automotive and defense industry products. Hexagon / Plastic injection machine advantages can be listed as follows;

   1. Lower costs

   2. Suitability for automation

   3. No need for post-processing

   4. Production at high speeds

   5. Suitability for production of parts with different surfaces, colors and shapes

   6. Very little material loss

   7. Ability to produce different products in the same mold

   8. Ability to work with low tolerances

   9. Operation with 220 v 3 KW energy

   10. Minimal space and footprint

​The plastic injection method begins with connecting the mold to the plastic injection machine and feeding the granular or powdered raw material into the hopper. The raw material is then heated and transferred into the bucket where it will be melted. The molten raw material in the barrel is passed through the nozzle under a certain pressure. Then, the molten raw material is conveyed to the mold, which is colder than the barrel, under gradually changing pressure. Meanwhile, the raw material is expected to cool in the mold for a certain period of time and the shaped product is taken from the mold by a pusher system, robot or manually. Once the product is received, the process starts again.

​Compact desktop plastic injection machine features and working principle ;

​* PLC and Panel Control Unit

* P.I.D Heat Control Unit – 6 Zones

* Injection Pressure Unit – 75 gr. 32 Tons ​

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* Mold Unit – 250 x 250 x 322 mm

* Vise Closing Unit – 32 Tons

* Hot Runner Control Unit

* Mold Temperature Control (Water Circulation)

* Machine Cooling Unit (Radiator – Fan)

* Water Circulation unit (Automatic)

* Evacuation mold pusher system (Mechanical)

* Raw material control system

* Production tracking system

* 1500 x 530 x 430mm

* 220 Volts – 50 / 60 Hz

* 3 KW ​

​​* 250 kg

​Injection Unit :

​In this section of the plastic injection machine, the raw material in granular or powder form is melted. This unit consists of funnel, screw, heaters, check-valve, injection nozzle and electromechanical units. The transfer of the raw material into the hive in an orderly flow is ensured by the funnel. The screw consists of 3 different parts where measurement, compression and feeding operations are performed. In the measuring section, the rate of raw material transferred from the tower to the screw is determined, in compression the raw material is melted at the desired degrees, and in feeding the molten raw material is transferred to the mold. The check valve is a device attached to the end of the worm screw mechanism. This apparatus does not allow the molten raw material to flow back. It also allows the screw to act like a piston.

​Mold Unit :

​It is a “set” that solidifies the molten plastic raw material after giving it the shape of the part. It is the mold cavity that creates the part geometry, and this cavity consists of two basic parts, male and female. In addition to these parts, the part design and optionally the manifold plate, cores, etc. that form the runner system. are other parts that can be found in a mould. There is a gating system that brings molten plastic from the injection bench to the mold cavity. A cooling system that solidifies the part quickly and evenly and provides healthy heat transfer is required. It has a pusher system that allows the part to be separated from the mold.

​Vice Unit :

​The vice unit is responsible for ensuring that the mold connected to the machine opens and closes and remains closed with high pressure to prevent burr formation. ​ This electromechanical system is controlled by an electromotor and works systematically with the pusher system with fixed mold dimensions.

​Control unit :

​These are systems that adjust all desired values ​​in the plastic injection process. The injection machines used have PLC control units. PLC (Programmable Logical Controller) is an automation device used in the control of processes such as production departments in factories or control of machines. This device works by scanning the input information at invisible speeds and responding to the appropriate output information in close to real time. PLC plays a major role in bringing to the fore elements such as producing more and higher quality products in a shorter time and producing with very low error rates.

​Stages :

​The manufacturing process of a plastic injection part consists of the following stages.

​Plasticization :

​Plasticization, the first step of the cycle, begins with placing the granulated or powdered raw material into the hopper. The raw material transferred from the funnel to the worm screw begins to melt with the heat released by the friction during the rotation of the screw and the heaters in the screw. The melting raw material reaches the screw cavity, and the raw material becomes ready to be conveyed to the mold. The plasticization stage is completed by simultaneously pushing the plastic accumulated in the screw cavity into the mold with high pressure. By adjusting the amount of material, the production measure is determined.

​Closing the Mold :

​In this stage, which is carried out by the vice unit in the injection machine, the two plates of the mold (male and female) close on each other. Thus, a mold cavity is formed and prevents the mold from opening against the high pressure and speed applied.

Injection :

​During the injection stage, the molten plastic material is sent into the mold through a nozzle at the end of the machine. The pressure and speed during this process are controlled by an electromotor. The raw material delivered to the mold cavity is compressed in the mold with the help of this pressure, and the raw material, which is warmer than the temperature of the mold, cools and freezes.

​Ironing :

​This process is applied to ensure that the part has the desired dimensions and that there are no errors in its appearance (depression, warping, bending, etc.). This is the stage where the pressure is highest. At this stage, the plastic melt injected into the mold is ensured to fill the mold cavity thoroughly by applying pressure. The process continues until the plastic becomes solid in the mold. The duration of the process varies depending on the characteristics of the raw material used, piece sizes and weight.

​Cooling :

​The injected melt causes the raw material to harden inside the mold. The plastic accessory hardened in the mold can be removed from the mold and used in almost every field of industry. Cooling of the mold is done through water channels inside the mold.

​Opening the Mold :

​The vice unit is opened so that the two sides of the mold are separated. When the part is removed from the mold, the cooled part remains on the moving side of the mold when the mold is opened, and the finished product is automatically removed from the moving side of the mold by means of cores or pushers, depending on the mold type.