Back injection machine

Types of back injection machines

A back injection machine is a piece of equipment used in the back injection molding process, which produces composite parts made of a flexible or rigid polymer and a rigid polymer, frequently used to manufacture high-quality and aesthetic plastic products. Different kinds of back injection machines exist to fulfill various industrial requirements.

• Hybrid back injection machines

  Hybrid back injection machines unite electrical and hydraulic movements to achieve injection and holding pressure, producing balanced quality and efficiency. The machines utilize an electric motor-driven screw for the injection phase and a hydraulic system for the packing and cooling phases. This combination grants precise control over the injection speed and pressure while ensuring reliable clamping force through hydraulics.

• Robotic back injection machines

  Robotic back injection machines employ robotics to enhance the injection process's flexibility, accuracy, or productivity. These machines usually consist of an injection unit that injects molten plastic into molds and a robotic system that manages the mold's operation. The robotic system can control the mold's opening and closing, inject the back layer into the mold, and remove the finished product from the mold. Additionally, the robotic system can be programmed to adjust the injection amount and speed according to different product requirements, achieving more precise control and higher production efficiency.

• Vertical back injection machines

  On a vertical back injection machine, the mold is vertical clamped, a molding technique with many benefits. It takes up less room. The injection component is located directly above the injection area. The machine can thus carry out injection and product removal in a single layer, requiring very little space for setup. As a result, vertical back injection machines are appropriate for operations that demand frequent mold changes and rapid production lines. To guarantee accurate molding results, they also offer excellent injection control and clamping force control.

• Microcomputer-controlled back injection machines

  Microcomputer-controlled back injection machines refer to machines whose operation and control are mainly based on microcomputer technology. These machines usually use a microcomputer as the central control unit to realize programmable control of the entire injection molding process. Through a user-friendly interface, operators can set and adjust various parameters according to production needs, such as injection speed, pressure, temperature, mold closing force, etc. At the same time, the machine can monitor the injection molding process in real-time, collecting and recording data, which is then analyzed to provide feedback to optimize production efficiency and product quality. Moreover, Microcomputer-controlled back injection machines also have self-diagnostic functions to quickly identify and troubleshoot equipment problems, ensuring the stability and reliability of injection molding production lines.

Specifications and maintenance of a back injection machine

Specifications

• Model: Fully automated back injection machines come in many models. Each model has unique features.
• Capacity: The quantity and weight of parts an injection machine can produce in a given time period are referred to as its capacity. The capacity of shooting machines varies based on their size and purpose, generally between 30,000 and 100,000 pieces per hour.
• Power: The electrical power required to run a shooting machine is referred to as its power. It usually ranges from 5 to 30 kilowatts.
• Gradients: The number of angles and gradients that a shooting machine can make molds for is called its gradients, which typically ranges from 10 to 100.
• Machine Size: A shooting machine's overall size includes length, width, and height in addition to the size of the molding cavity and the size of the carrying system. The dimensions are usually around 5 meters, 3 meters, and 2 meters.

Maintenance

• Regular clean: Regularly remove the dirt and waste in the injection machine. Use the appropriate cleaning solution and cloth to wipe the surface of the injection machine, mold cavity, and pipeline, which can ensure the injection machine's cleanliness and hygiene.
• Lubrication: Regularly add lubricating oil to the moving parts, such as slide rails and gears, of the back injection machines. This can ensure the smooth operation and reliability of the injection machines.
• Parts inspection: Periodically inspect the key components of the injection machines, such as molds, heating elements, and pump units, to check for wear, damage, or blockage, and timely repair or replacement as needed.
• Dust removal: Regularly clean air filters or dust in ventilation systems of the injection machine to ensure that the equipment has sufficient and clean air for injection molding.
• Calibration: To ensure the accuracy of material injection and molding ratios, periodically recalibrate the flow rates and ratios of back injection machines according to the operation manuals of the respective injection machine models.
• Inspection and maintenance of electrical parts: Check the electrical components of the injection machines and connection lines periodically, ensuring that they are free from corrosion, loosening, or damage. Furthermore, ensure that the injection machine operates properly and safely by fixing or replacing any malfunctioning parts.

Application scenarios of back injection machines

The high-speed back injection machines offer numerous benefits across different industries. Here are some application scenarios for back-injection and Mexican back-injection machines.

• Automotive industry

  The back injection machine creates diverse complex automotive interior components, including trims, panels, structures, and seats. The machine makes parts that meet the required specifications for quality, aesthetics, and functionality. Back-injection machines also enhance the component's performance by increasing the strength of the plastics with the elastomeric materials.

• Construction Industry

  This industry employs a back-injection machine to manufacture building parts like doors, window frames, wall panels, and flooring. These are usually made from a combination of rigid and soft polyurethanes to increase strength and durability. Components made with this machine are impact-resistant, energy-efficient, and noise-dampening.

• Furniture Industry

  The back-injection machine custom-makes ergonomic furniture pieces like office chairs, gaming chairs, and other seating solutions. The combination of hard and soft plastics can better provide quality seating components with differing levels of softness. The soft seating areas will have enhanced cushioning, while the hard surfaces will have improved resistance to abrasion and wear.

• Consumer goods and electronics

  These industries use the back-injection machine to manufacture durable and aesthetically pleasing products like mobile phone cases, remote control housings, and kitchen appliances. Using this machine increases the durability of the item, and the remote control and phone casing will look better because of the colorful designs on the back.

• Medical devices

  Medical devices require high precision and sterile conditions. A back-injection molding machine efficiently makes diagnostic equipment, surgical instruments, and drug delivery devices. The combination of two or more materials can enhance the product's mechanical qualities. Hard plastics are more potent, while soft plastics can offer better cushioning and resistance to impacts.

How to choose a back injection machine

When choosing a back injection molding machine for a specific application, several factors need careful consideration.

• Production volume and part complexity

  These two factors are the primary determinants of whether a business should invest in a primary or secondary back injection molding machine. If they make complex, high-value items in low volumes, they should go for cheaper options like the secondary machine. However, for intricate items needed in large volumes, primary machines might be the better choice.

• Features

  Modern machines come with cool features like computer controls, built-in molds, and fast-cycling abilities. While these machines can boost production, they tend to be more expensive. Businesses should weigh the advantages of these features against their costs before buying the machine.

• Future Needs

  When choosing a machine, it would help to consider the business's potential growth. Select a machine capable of meeting the needs of future growth in demand. However, it is also essential to strike a balance and avoid getting a machine that is too big for current requirements.

• Compatibility

  Ensure that the machine is compatible with existing materials, molds, and production processes. Injection molds for back-injection molding are usually different from those for standard injection molding, so it is essential to check compatibility before buying.

• Total Cost of Ownership

  It is essential to look beyond the upfront purchase cost and consider the total cost of ownership. This includes operating costs, maintenance requirements, and any potential resale value. Choosing the machine with the lowest total cost of ownership can help maximize the return on investment.

Back injection machine Q & A

Q1: Which types of molds can be used in a backing injection machine?

A1: Generally, the injection backer machines use cast molds. The backing material is injected into the cavity of the mold, which has the shape of the desired part. Other molds used in the injection machine include:

• Flexible molds: They are typically used for lower-volume production runs or prototype parts. Usually, they are made from materials like silicone or urethane.
• Composite molds: They are made from a combination of materials, such as a rigid substrate with a flexible cover. Composite molds can be used for back injection molding when the design requires complex geometries or undercuts that conventional molds cannot achieve.
• Direct molds: Also called master molds, they are used for high-volume production. They are typically made from metal and are expensive and time-consuming to create.
• Rim molds: The molds used for reaction injection molding, which is a different type of injection molding, are made from polyurethane or other materials. They are sometimes referred to as RIM molds.

Q2: What are the advantages of using a back injection machine in manufacturing processes?

A2: The following are some benefits of a back injection machine to a manufacturing facility:

• Design flexibility: One of the key benefits of using a back injection machine is that it allows manufacturers to create parts with complex geometries and designs that would be difficult or impossible to achieve using other molding techniques.
• Multi-material molding: The back injection machine enables the combination of two or more materials into a single part, improving the function and performance of the resultant parts.
• Waste reduction: The back injection machine's efficiency helps to minimize material waste during the manufacturing process. This is because the machine precisely controls the amount of injected material required to fill the mold cavity, reducing excess and scrap production.
• Production scalability: Depending on the increased production volume, the scalability of the back injection machine means the same machine can be programmed to produce larger quantities of parts without requiring additional equipment or investment.

Q3: How does one choose the right back injection machine for a specific project requirement?

A3: Knowing the following features of the machines will help one choose the best machine for the project:

• Molding capacity: The molding capacity of the machine refers to the maximum amount of material the injector can inject in a single cycle.
• Control system: Modern injection machines have computer-controlled injection speeds and pressures.
• Energy efficiency: Consider the machine's energy consumption and efficiency. Look for models with energy-saving features.
• Tooling compatibility: Ensure the machine can accommodate the tooling required for the specific parts being produced.