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Midstate Mold & Engineering

Precision Plastic Injection Molders

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How Prototype Tooling in Injection Molding Accelerates Production

Two bottle-shaped plastic injection molds laying side by side meant to demonstrate prototype tooling in injection molding.

Many believe prototyping is just an extra, unnecessary step in the injection molding process, which is a misconception that can result in severe production line disruptions and forfeiture of time and money. In fact, some believe it increases costs and inhibits development and production times, but in reality, it does the opposite. Proceeding with a custom injection molding without prototyping often results in a series of tool adjustments that can become both time-consuming and expensive. Let’s review precisely how prototype tooling in injection molding accelerates production and saves you time and money.

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How to Avoid Warpage in Plastic Injection Molding

A close-up of red, warped plastic meshed atop similarly warped mesh of varying colors.

Warpage can be one of the more frustrating injection molding defects, as it can range from a simple aesthetic problem to an issue that compromises the entirety of the part’s function. This defect can result from any number of variances occurring within the injection molding process. Fortunately, a combined knowledge of plastic flow behavior, material science, and machine and tool settings can prevent this defect. Let’s discuss how experienced manufacturers avoid warpage in plastic injection molding.

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Force Majeure Declarations Affecting Plastic Injection Molders

A pandemic face mask discarded on snowy ground to represent the force majeure faced by manufacturers due to a combination of COVID-19 and the Texas snowstorm

A frustrating combination of disrupted supply lines from the global pandemic and the recent storm that devastated Texas has led to limitations in resin availability. As with any industry, this is creating a disparity in supply and demand, resulting in soaring plastic prices and force majeure declarations – meaning an inability to fulfill a contract due to an unforeseeable circumstance. This has led to some vendors revising part specifications or material requirements to sidestep the crisis. Let’s take a closer look at the recent and frequent force majeure declarations and their effects on plastic injection molders.

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Achieving Success with Undercuts in Injection Molding

A hand holding the snap and latch part of a black backpack, an example of an undercut used in plastic injection molding.

Undercuts can be defined as any protrusions, cavities, or recessed areas of a part that run parallel to a mold’s parting line. If undercuts are required for a particular part, it can complicate the injection molding ejection process, as the friction can interfere with the part’s separation from the cavity. Fortunately, if a part calls for undercuts, an expert injection molder will be able to apply additional tooling and engineering techniques to facilitate this separation.Let’s discuss some of the ways of achieving success with undercuts in injection molding.

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Injection Molding Thermoplastic Highlight: Polyethylene

Close up of polyethylene corrugated tubing used for electrical installation.

Plastic injection molding is ideal for achieving fast production of a vast array of parts. This wide range of applications is made possible due to the large selection of thermoplastic materials – one of the leading examples being polyethylene. This polymer is one of the most widely produced plastics in the world, and its many subtypes make it suitable for any number of complex designs. To truly understand the benefits of this polymer, let’s take a moment to highlight the injection molding thermoplastic, polyethylene.

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How Melt and Mold Temperatures Cooperate to Form a Final Product

A close up image of the screws that guide melted plastic into the plastic injection mold.

Experienced manufacturers are aware that certain conditions in the injection molding process have a large bearing on the properties of the final product. Two important elements in the process that weighs heavily upon a part’s performance requirements are proper melt and mold temperatures. In order to truly appreciate the collaboration of these two stages and how they produce higher qualities parts at a lower cost, let’s take a look at how melt and mold temperatures cooperate to form a final product.

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