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Plastic injection molding has been providing plastic molded parts for almost two whole centuries now and counting! If it wasn’t for the the brilliant minds of those in the field, we may be without hundreds of things that we’ve so far grown dependent on. The plastic molding process is responsible for producing things as commonplace as keyboards, toys, and power tools, so you can see how vital it is to our current way of life. Since starting out on my custom plastic extrusion research, I have gained such a vast array of information on its history and its current workings, that I have been compelled to let other people know about it. The thing that surprised me the most about the process was how little I had heard about it until just recently! You would think that with something so widely used, producing so many important amenities, that conversations about it would be as commonplace as the products it produces! So what is this plastic manufacturing process, and where did it come from?

Throughout the course of industrialization, there has been a lot of pressure on the reduction of industrial waste. This is because many industrial processes can be harmful to the environment, but plastic injection molding is actually one of the safest! Since plastic injection is used in such frequency, it’s a good thing that it isn’t highly dangerous to the environment, otherwise we’d have to look for new ways to produce so many things. Thankfully, plastic injection has been fine-tuned to perfection ever since its debut in 1868.

Injection molding was invented by John Wesley Hyatt in 1868; this was the first time the process had ever been seen before. He began to make billiard balls by injecting a material called celluloid into sphere-shaped molds. Celluloid was invented in the 1820′s, and was most often used because it looked similar to ivory or bone. Soon after his first steps into plastic injection molding, Hyatt looked to make the process easier on himself, so he created the very first injection molding machine (which employed the use of a plunger-type piece).

Soon, the word began to spread about plastic injection molding and all of its benefits, and little by little it started to expand. The machines were revolutionized, and by 1946, a man by the name of James Hendry had completely transformed John Wesley Hyatt’s original model for the plastic injection molding machine. Instead of a plunger technique like Hyatt’s, Hendry implemented a large industrial screw, which proved to be much more efficient. This made it so much easier to create exterior panels, and sell more of them for a cheaper price to both consumers and producers.

When purchasing a plastic to use in the injection molding process, manufacturers have a few variables to cover. These can include the budget that the company is running on, the type of product being made, and the estimated output quantity. Most plastics, however, come in the form of small beads or pellets, often referred to by those in the industry as resin. Common types of plastics used in the process are acrylic, teflon, delrin, polyvinyl chloride (PVC), polyamide, polystyrene, and more.

The tricky thing about plastics, and something to always be aware of, is that they are non-degradeable, so they aren’t good for the environment. Plastic injection molding, however, is a much safer way of processing plastics and it even reduces waste. The plastics are able to be used and reused as many times as you want, so that’s really another important reason to reduce, reuse, recycle! Also, plastic injection molding companies are aware of which plastics are not safe for consumer use, and work to provide the safest means of producing non-harmful products.

The plastic beads, or resin, are then put into the first part of the machine called the feed-hopper, which allows the resin to be gravity-fed into a barrel-shaped heating device. The screw begins to twist and turn through the plastic as it falls from the barrel, it forces the plastic to essentially stir itself as it begins the melting process. According to a designated temperature set by a specialist, it usually heats up to about 400 degrees Fahrenheit. If overheating occurs, which is sometimes a concern, the heaters automatically shut themselves off and cooling fans turn on, as the molten plastic retains its optimum temperature by force alone.

Then, the plastic goes through a filtering device to rid it of any contaminants it may have collected. By doing this companies eliminate the risk of ragged edges, or plastic products that simply aren’t uniform. Finally the plastic enters a die, whose primary purpose is to form the mold into the shape of the final product. Molds can be made of expensive steel, but this proves to be much more durable, if a company is watching its expenditures they can opt for the less durable aluminum or beryllium-alloy metal.

There’s a cooling process where the molded parts are placed into a bath-like holding center, and then shipped out to consumers everywhere. Plastic  molding is far more important than you think, it’s responsible for things as vital as hurricane shutters! The whole extrusion process only takes just a few minutes, contact a plastic extrusion company for more information!

Sanding & shaping resin kitchen cabinet door knob.

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