Spray-free materials’ requirement on Injection Molding Parts and molds:
1、High gloss and high brightness,
2、the mold should use high gloss steam mold and the ABS Injection Molding parameters use high temperature and high pressure state,
3、The mold material should choose the wear-resistant material,
4、For single gate mold, it should select the appropriate gate location and gate shape according to product size,
5、For multi-gate Plastic Injection Molding Products, the gate type should be in order.
Spray-free materials’ requirement on the product structure design:
1、Less holes,
2、Less ribs,
3、Avoid complex structures.
The common spray-free resins are ABS, PMMA/ABS, PC/ABS, high gloss ABS, these materials are suitable for use in products that require better surface glossy. But not all of the product structure can be used spray-free material, especially for the products that has hollow structure on the surface; the back surface has a lot of screws, buckles, strenghten ribs; the thickness is nonuniform. Above 3 kinds of typical product structures that are easy to has flow marks and welding lines. But not only limited to these 3 types. These complicated product structures are prone to these problems. In order to improve these issues, the 4 factors of product structure, mold structure, molding technology and material should be realised at the same time. So the use of spray-free material in the actual product application requires rich experience and system solution to ensure the project smooth progress.
1、Has hollow structure on the product surface
For ordinary dyeing materials, the weld line is only a small line, but for spray-free material, the "visually" welding line on both sides will have differences colors, so that welding lines appear more obvious. Therefore, the structure with hollow on the product surface generally isn’t suitable to use spray-free material to injection molding directly.
2、The back surface has a lot of screws, buckles, strenghten ribs
During injection, when the material filling to screw stud, it will have diversion and cause the problem or flow marks.
3、the thickness is nonuniform
The nonuniform thickness will form a parting line on the surface.
Summary
Although, spray-free has many benefits, but for these complicated structure, it is still difficult to deal with and its application is still relatively limited. However, spray-free products are widely used in: refrigerator panels, air conditioning panels, decorative strips, speaker panels and base, LCD TV panels, small appliances shell, cosmetics packaging, etc.
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