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plastic injection moulding

Injection Moulding of Plastic Products

Injection moulding at AKF Plastics: AKF Plastics has everything for a carefree injection moulding production.

AKF Plastics is your ideal partner for supplying high-quality injection moulding solutions. Our rich history, experience and portfolio covers a wide range of industries. Our focus is producing plastic products and parts for following markets and others:
  • Automotive industry
  • Aerospace
  • Building & construction

Plastic injection moulding opportunities

Micro Injection Moulding

Our machinepark includes injection moulding machines in a wide range. That starts for micro-injection moulding with a specialist 12 ton Boy 12A injection moulding machine.

This injection moulding machine is equipped with a screw with a diameter of 12 mm and has a maximum shot volume of approximately 4.6 cm3 (+/- 4.42 grams), especially for micro injection moulding. For the smallest dimensions, this machine has a very small shot volume with a high tolerance. With this machine micro products can be made with weights of less than 0.03 grams each.

Reach injection moulding machines

AKF Plastics has a complete range of injection moulding machines, starting at 12 tons and ending at 900 tons of clamping force. Thanks to this injection moulding machine, our production capacity starts with the smallest possible injection mouldable product. This allows us to work from a shot weight of less than 0.03 grams. The larger injection moulding machines reach a size of 900 tons closing force with a maximum shot weight of 5,900 grams.

Automation

Our injection moulding production is largely automated through specialised handling and finishing and installations. These are mainly used for handling, finishing and fully automated packaging of products. That way production can be done 24/7.

Which materials are suitable for injection moulding?

Many plastics are suitable for injection moulding. We offer you products from all conceivable and possible materials, possibly with fillers or additives in almost any color scheme. It uses fillers such as glass fiber, glass pearls, carbon fibers, stainless steel fibers, Twaron fibers, chalk, talc, and so on.

The only exception to this is the material PVC (Poly-Vinyl-Chloride). The machinery, infrastructure and injection moulds are not suitable for this.

  • Polyolefins: PP (Poly-Propylene), PE (Poly-Ethylene; HD – High Density / LD – Low Density) and PS (Poly-Styrene)
  • Combination fabrics: 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-Theraphthalate), PBT (Poly-Butene-Theraphthalate) and various combinations of engineering plastics
  • High-tech (high-resistant) engineering plastics: PPS (Poly-Phenylene-Sulfide), PSU (Poly-Sulfon), PES (Poly-Ether-Sulfon), PEI (Poly-Ether-Imide) and PEEK (Poly-Ether-Ether -Ketone).
  • Special fabrics: PFA – Teflon (injection moldable)

High-quality Injection moulding production

AKF Plastics strives for high-quality injection mould production. We give substance to this by always working to deliver added value for our customers.

Plastic Injection Moulding Techniques

AKF Plastics uses various techniques in the field of injection moulding. The choice of a specific injection moulding technique depends on your project, your wishes and requirements, but also on our advice in the field of technical and economic manufacturability.

Here you get an overview of the injection moulding techniques that we apply in our daily injection moulding activities for various plastic products:

Standard injection moulding; with standard injection moulds.

Mould types; thanks to our versatile machine park, we can process all imaginable types of injection moulds. Think of hot-runner moulds, moulds with pneumatic control, ejection or support, moulds with hydraulic cores, core pullers or cylinders, or multiple moulds.

Inserts of metal, stainless steel, bronze, aluminum or plastic can be used for the final technical application of our products. These are injected into the product during injection moulding. This creates a very strong connection thanks to the mechanical encapsulation of the insert in the plastic. These inserts are mainly used to make a connection or other type of contact with another part. Inserts are much firmer than hitserts. These are also metal parts that are hot pressed after injection moulding.

Producing 1-piece hollow injection moulding products. Normally, injection moulding is not a suitable technique for forming hollow plastic products in one piece. With the lost cores method, a metal inner core is first cast. This is then sprayed with plastic. After that, the metal inner core can be melted from the product because the melting temperature of metal is lower than that of the plastic.

This creates a hollow injection moulded product without connections. This method is highly specialised and expensive, so we only carry it out when the application of the product justifies the costs. In this way, for example, we produce aircraft handlebars for the aviation industry.

If the product geometry is so complex that it cannot actually be demoulded, we use metal inlay cores. These insert cores are pre-inserted into the injection mould by hand. We then injection mould the product around it. Then the whole of product and metal inlay cores are demoulded and ejected. Then a second set of insert cores is inserted into the injection mould and the injection moulding process starts again. During this cycle, the inserts are removed from the already formed product.

This creates a hollow injection moulded product without connections. This method is highly specialised and expensive, so we only carry it out when the application of the product justifies the costs. In this way, for example, we produce aircraft handlebars for the aviation industry.

‘Spritzpraegen’. We have an injection moulding machine that can squeeze presses in the range of 220 tons. With injection moulding, the mould cavity of the mould is closed during or after the injection. In this way, the injection moulded products are not only injected, but also pressed into the same production run. For example, the injection pressure is lowered and injection moulded products can be made with less stresses present. This is how we produce lenses, for example.

We produce many products that must be built into technical installations. Flatness and straightness are often important themes. Because plastic injection moulded products always shrink, it may be necessary to impose straightness and squareness. For this we use post-shrink moulds that ensure that the plastic products continue to assume the correct straightness and squareness after injection moulding.

Forced satiety. With some injection moulding products from hygroscopic materials it is important to immediately maximize the potential water absorption. This is the case, for example, with P.A. 6, with a possible moisture absorption up to 10% volume. Such injection moulding products are placed in water baths immediately after injection moulding, so that maximum moisture absorption takes place. As a result, later moisture absorption plays a less important role.

Some products that we injection mould require a particularly high tolerance that cannot be achieved with injection moulding without losing reproducibility due to moisture absorption and shrinkage. After injection moulding, these plastic products are transferred to the CNC machines in our finishing department. There they are finished by milling and turning them if necessary. In this way, the vast majority of the process is injection moulding, providing cost efficiency, and the high accuracy and tolerance is applied mechanically.

Free eGuide with Tips & Advice Supplier Selection

To answer the most frequently asked questions, we have compiled a handy eGuide series with Tips & Advice. Part 2 provides insight into how to select the right supplier, cost structure, price structure and our vision on quality.

Would you like to know more about our services and products? Please feel free to contact us, we are happy to assist you.

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