With industrial injection molding, Proto-Cast LLC can help you solve part problems, from weight reduction to elemental resistance. We have been helping companies create unique, durable parts for over 50 years. Today we will look at 3 examples of how industrial injection molding created successful parts.
Case Study #1: Smooth Sailing
A manufacturer came to Proto-Cast, LLC with a new design for one of their patented retractable boat shades. This new design required several injection molded parts. Four of these parts were cylindrical sleeves with keyways molded into each. The severe differences in wall thickness normally result in the parts being affected by shrinkage. The challenge was for us to reduce overall shrinkage while meeting the superior strength and resistance to elements these parts require.
Our engineers combined precise machining with a Delrin® 577 – 20% glass filled material to produce the cylindrical sleeves. The 20% glass additive gives structural strength while a UV inhibitor protects against the harsh elements. We set the machine processing parameters to reduce overall shrinkage, insuring the part keeps its shape and functions properly. The result was an innovative product now enjoyed by boaters around the world.
Case Study #2: Leveraging the Benefits of Plastic
A rail transportation company was using a train brake lever made from forged metal. This brake lever had to be carried by the train engineer at all times, but it was quite heavy. The company reached out to Proto-Cast, LLC to see if the lever could be injected molded instead, significantly reducing its weight.
Examining the lever, we found that traditional industrial injection molding techniques and resins could not be used due to the part’s thickness and geometry. Thinking outside the box, we turned to a chemical foaming and nucleating agent called Safoam®. By blending Safoam® with Verton™ Nylon6/6 with 50% long glass fiber filled resin, we achieved the desired weight reduction without having to alter the geometry of the part. The foaming agent improved dimensional stability, cycle times, and stiffness of the part while the long glass fiber filled resin provided the necessary strength. The new, lighter lever is much easier to carry at all times.
Case Study #3: Paving the Way
An LED hardscape lighting manufacturer designed a new paver that houses the LED board inside a channel cavity. Forming this channel cavity with industrial injection molding means drilling two through holes so the cavity core can be held in place during the molding process. The holes would then have to be sealed prior to assembly in order to prevent exposure to outdoor elements and withstand the heat produced by the LED lights.
As a necessary part of the molding process, we could not eliminate the through holes from the design. Instead, Proto-Cast, LLC created a cavity in the mold that would produce a tapered plug which could be ultrasonic welded into the hole after molding. Ultrasonic welding is a reliable way to join thermoplastic materials and insure the integrity of the bond. These pavers can now light up walkways without the risk of being compromised by the elements.
Industrial Injection Molding from Proto-Cast, LLC
If you have a challenging part, Proto-Cast is here to help. With 50 years of experience and strict adherence to ISO 9001-2015 standards, we can turn your problem part into a reliable solution. Call us today at 610-326-1723 for more information.