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Plastic product casting

The Company "Variant-Plus" has at its disposal high-performance injection molding machines. The equipment allows you to make custom products made of plastics (plastic) of various configurations, complexity and size up to 130 * 130 mm. The injection molding method is used in manufacturing.

The production uses new equipment with a service life of no more than three years, which minimizes the duration of the plastic casting cycle and ensures a high level of quality of manufactured products.

The fundamental principles on which the production of «Variant-Plus» plastic injection molding is based are environmental safety and high quality standards of manufactured products.

We offer our customers a full package of plastic casting services: from mold manufacturing to mass production in accordance with modern Ukrainian and European standards.

The company employs highly qualified specialists with more than 10 years of experience. We have our own design, technology and tool departments. Quality control is carried out in accordance with international standards.

Quality tools such as MSA, SPC, FMEA, IBS, etc. have been implemented. documentation on automotive components is maintained in VDA format.

Custom pressure welding operations

Efficient and highly performance way

Pressure welding operations are an efficient and high-performance way to produce products. In this way, tens and hundreds of thousands of in-line products are produced, which is optimal from the point of view of financial and time costs.

Advantages of injection molding:

    • Possibility of recycling various types of plastic.
    • Full automation of the plastic injection molding process.
    • The ability to manufacture parts of complex shapes with great precision, which is not always possible to achieve when using other plastic processing technologies.

    Products created by this method can be reinforced, hybrid or hollow, colored or foamed.

    Possibility of Forming Products of different weights.

    Thanks to the peculiarities of technology and equipment, you can create a wide variety of products. Custom casting of Engineering Plastics is carried out using injection molding machines (TPA). At the same time, the casting method itself is cyclical, and its essence can be reduced to the following.

    1. First, the polymer material under the influence of temperature passes from a solid to a viscous state.
    2. Then the polymer melt located in the cylinder of the casting machine is fed into the mold by means of a screw.
    3. The mold is evenly filled with polymer composition. The melt is cooled, and the material cylinder is closed to the mold system.

    After the product cools down, the mold opens and the product is removed from it.

    The equipment is selected depending on what type of plastic casting will be used.

    Injection molding

    With its Help, plastic products are obtained with minimally thin or as thick walls as possible, they give less shrinkage. The process itself is the injection of a molten polymer mass into a mold that is not completely closed.

    Intrusion

    This method is necessary for obtaining plastic products with thick walls. Its operation is based on injecting less material into the mold than required. The mold is filled with a liquid polymer melt under low pressure. As soon as it is filled, a small amount of material is supplied under high pressure — it is this material that finally forms the product and compensates for its shrinkage.

    Granulated thermoplastics are most often used as raw materials. Products made from them can then be recycled.

    In addition, a common material is thermosetting powder. During its processing, irreversible solidification reactions occur, which lead to the formation of a non-melting product. Further recycling is not possible.

    Our goal is to get high-quality products with maximum productivity!

    Production of plastic products by injection molding

    This process can be divided into several stages:

    • mold design and manufacturing;
    • preparation and development of the composition of raw materials, creation of compositions based on a polymer matrix with the addition of dyes and other additives. At this stage, the requirements for the finished product are taken into account.
    • selection of raw material processing method;
    • direct plastic injection molding.

    Welding operations must be carried out in strict accordance with the selected technology. At the same time, you should strictly observe the time and temperature conditions.

    Manufacturing of products is carried out using blanks. Their number depends on the customer's needs, as well as the product range. After feeding the polymer raw materials, the finished product is removed by the ejection system. The temperature is adjusted using ordinary water. It is fed into the cooling channels.

    The structure of the plastic injection mold is a device for manufacturing objects of various shapes and complexity. In a typical blank, there is a matrix (fixed element) and a punch (movable part). The flatness of these parts acts as a negative impression of the outer surface of the product. Most often, multi-seat blanks are used. They produce several parts at the same time.

    It should be noted that the direct process of manufacturing molds is always individual and quite complex.

    The plastic casting process is carried out in compliance with the temperature regime. In particular, when processing raw materials, the press billet is thermally controlled or heated. The first operation is performed if thermoplastics are used. The temperature of the press billet in this case should not be higher than during crystallization or glass transition. If reactoplastics are used, the mold heats up. Its temperature should reach the level at which solidification occurs.

    The pressure of plastic injection molding will depend on several factors: the design of the mold, the viscosity of the molten plastic, the size of the finished parts and the injection system. In the process of filling the cavities, it gradually increases. Pressure reduces the residual stress in the raw material, increases the degree of orientation of crystallizing elements (polymers). This helps to increase the strength of the material, as well as more accurate reproduction of the dimensions of parts. The pressure distribution along the length of the cavity is uneven, which is due to the high viscosity of the melt and its rather rapid increase during cooling.

    To equalize the pressure when casting products made of Engineering Plastics, pre-compression of the material is used. It is carried out on an installation, the nozzle unit of which is equipped with a crane. It is closed and raw materials are prepared. The melt is compressed in the material cylinder to the casting pressure. Then the tap is opened and the plastic is fed into the cavities. The melt fills the molds at a sufficiently high speed, and under the influence of the friction force, it is additionally heated. In some cases, mechanical destruction of the material may occur. To prevent it, limit the feed rate of the melt. Due to pre-compression, the cavity filling time can be reduced by 1.5-2 times.