Plastic injection moulding
Injection molding of plastic products
Injection moulding at AKF Plastics: AKF Plastics is fully equipped for injection moulding.
We process a wide variety of materials and apply them for an extensive range of injection moulded products for several markets. All common plastics are processed and virtually any injection moulded product can be handled by us, in some cases even including any after-work, rework and / or assembly, logistics and warehousing. Our focus is producing plastic products and parts for following markets and others:
Plastic injection moulding possibilities
The range of our injection moulding machines starts at the bottom with a specialistic 12 tonnes Boy injection moulding machine 12A for micro-injection moulding.
This injection moulding machine is equipped with a screw having a diameter of only 12 mm and has a maximum shot size of approximately 4.6 cm 3 (+/- 4.42 grammes). In praxis this machine has a very small shot size with an extremely high accuracy. With this machine, micro products are made with weights less than 0.03 grammes each.
AKF Plastics offers a full range of injection moulding machines starting at 12 tonnes up to 900 tonnes of clamping force.
Our smallest injection moulding machine of 12 tonnes is one of the world’s smallest injection moulding machines and as such our production capacity begins at the smallest possible (injection mouldable) products. We start at a production capacity of less than 0.03 grammes and increase up to of 5,983 grammes.
One of the present technologies is the use of 6-axis controlled robots. We also also use linear robots. We use robot technology of Reis Robotics. Our injection moulding production is highly automated by means of specialized handling and after work stations and cells. These are mainly used to handle, after work and fully automatic packing of products. This enables 24/7 production.
Due to the vast amount of and variation in products and productions automation is always carefully assessed and analysed.
Which materials are suitable for injection moulding?
Apart from this specific material, AKF/AGF Industrie BV is able to offer you products from all conceivable and possible materials, if so required equipped with fillers and / or additives in virtually (final colors to be determined on request) any color. Available is the use of fillers such as glass fiber, glass beads, carbon fibers, stainless steel fibers, Twaron fibers, chalk, talcum, etc.
The only exception to this is the material PVC (Poly-Vinyl-Chloride). The machinery, the infrastructure and the injection moulds are not suitable for this.
- Poly-olefins; PP (Poly Propylene), PE (polyethylene, HD – High Density / LD – low density) and PS (Poly-Styrene).
- blends; ABS (Acrylonitrile-Butadiene-Styrene), ASA (Acrylonitrile-Styrene-Acrylate), PMMA (Poly-Methylene-Methyl-Acrylate), SAN (Styrene Acrylo Nitrile-) and SEBS (Styrene-Ethylene-Butadiene-Styrene block copolymer).
- Flexible and soft plastics; TPE (Thermo Plastic Elastomer-) and TPU (Thermoplastic Poly-Urethane).
- Engineering Plastics: POM (Poly-Oxy-Methylene), PA (Poly Amide) types 6, 6.6 and 12, PC (Poly-Carbonate), PET (Poly-Ether-Theraftalate), PBT (Poly-Butene-Theraftalaat) and various blends (combinations) of engineering plastics.
- High tech (high resistant) engineering plastics: PPS (Poly-Phenylene-Sulfide), PSU (Poly Sulfone), PES (poly-ether sulfone), PEI (Poly Ether Imide) and PEEK (Poly Ether Ether Ketone).
- Special: PFA – Teflon (injection moulded).
High-quality injection moulding
AKF Plastics aims at high performance production. We do so by continuously working towards added value for our customers.
Injection moulding techniques
AKF Plastics applies a variety of technologies in the field of injection moulding. Depending on your needs and requirements as well as our advice on technical and economic feasibility we will apply a distinctive technology.
We’ll give you an imporession of technologies applied in our daily injection moulding operations:
Standard injection moulding; with standard injection moulds.
Mold types; Due to our equipment and machinery we are able to process all kinds of injection moulds: hot-runner moulds, moulds with pneumatic actuation of slides and/or cores, moulds with pneumatic ejection or support, moulds with hydraulic cores and/or slides or multiple-cavity moulds.
Producing hollow injection moulded products out of one piece. Normally injection moulding is not suitable to create hollow plastic parts out of one piece. With the lost core method, a metal inner core is first moulded. This is then inserted into the injection mould and moulded (covered) with plastic. Thereafter the metal inner liner is removed by a melting process (Tmelt metal
If the product is of such complex geometry that it cannot demould properly, we make use of metal inlay cores in the mould. These inlay cores are pre-inserted by hand into the injection mould. We then injection mould the product around it. Then, the combination set of product and metal inlay core(-s) is demoulded. Then, a second set of inlay cores is inserted into the injection mould and the injection moulding process begins again. During this subsequent cycle, the inlay cores are taken out of the already formed product manually.
In the range of 220 metric tonnes of clamping force, we have a machine available which can perform compression moulding. In compression moulding the mould cavity is closed during or after the injection phase. In this way, one can make injection moulded products which are not only being injected, but also, compressed in the one and the same process. In this way the injection pressure is being reduced which results into products with less internal stress. This method is for example being used in tha manufacturing of optical lenses.
We manufacture a great deal of components to be installed and assembled into engineering equipment and/or machinery. For such components dimensional stability as well as being as straight as possible is of paramount importance. Since plastic injection moulded products always show (after-)shrinkage behaviour, is may become necessary to impose a certain geometry after moulding. In such cases we use cooling jigs to ensure dimensional stability and geometrical optimalization.
Controlled saturation. For some injection moulded products out of hygroscopic materials (for example, P.A. 6, up to 10% of volume moisture absorption), it is important to bring the potential water uptake instantly to a maximum. Such injection moulded products are instantly fed into a water bassin directly after moulding to maximize water absorption. As a result these products are less sensitive to subsequent moisture absorption in alter stage of the product life cycle.
Some products we injection mould require such a high level of dimensional tolerance that it can virtually not be achieved by injection moulding, or at least not in a way that, with respect to moisture absorption and shrinkage, is controllable over a batch of products. Such products are routed into the CNC department of our department of after works; turning and milling. In this way, the vast majority of the costs is absorbed by injection moulding (cost effective) and the high accuracy and tolerances are made mechanically.
Free eGuide with Tips & Advice: selecting your supplier for your injection moulding.
To answer the most frequently asked questions, we have compiled a handy eGuide series with Tips & Advices. Part 2 provides insight into how you can select the right supplier, cost structure, price structure and our vision on quality.
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