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Improving Metal Injection Molding Quality with Hot Runner Systems

Metal Injection Molding (MIM) is a popular manufacturing method for producing complex metal parts. It offers a wide range of design possibilities, improved part precision, and high yield rates. However, MIM is not without its challenges. One of the primary obstacles to success is the formation of defects such as porosity and shrinkage.

Hot runner systems, also known as hot manifolds, are a valuable tool for addressing these issues. These systems work by keeping the plastic melted and at a consistent temperature as it flows into the mold. The hot runners provide a direct path for the molten material, ensuring that it doesn’t cool or solidify prematurely and creating a smoother flow of material into the mold.

When applied to metal injection molding, hot runner systems can significantly improve the quality of the final product. Here are some specific ways that hot runners can enhance the MIM process:

1. Reducing the number of defects: By keeping the molten metal at a consistent temperature and flow rate, hot runners can prevent the formation of porosity and shrinkage. These defects are formed when gas or solid particles get trapped in the molten metal, leading to structural weaknesses in the finished part. With hot runners, the molten metal is kept free from these contaminants and the final part has a more uniform and reliable structure.

2. Improving part consistency: With traditional MIM methods, it can be challenging to maintain consistent pressure and temperature throughout the injection process. This can lead to variations in the final part, making it difficult to achieve the same level of precision and quality across multiple production runs. Hot runners help to maintain a more stable flow of material, resulting in parts that are more uniform and consistent.

3. Decreasing cycle time: Because hot runners provide a more efficient and direct path for the molten metal, they can reduce injection time and overall cycle time. This can result in faster production rates and lower costs.

However, implementing a hot runner system requires careful consideration and planning. Here are some factors to keep in mind:

1. Mold design: Hot runner systems require specific design considerations to be effective. The mold must be designed to accommodate the hot runner system, including considerations for temperature control and part ejection.

2. Material selection: Not all metals are compatible with hot runner systems. Some metals, such as stainless steel, may require special treatment to prevent corrosion or other damage.

3. Cost: Hot runner systems can be more expensive than traditional injection molding methods. However, the benefits in terms of improved part quality and consistency can outweigh the additional cost.

In conclusion, hot runner systems provide a valuable tool for improving the quality of metal injection molded parts. By reducing defects, improving consistency, and decreasing cycle time, they offer a range of benefits to manufacturers. While there are specific considerations that must be taken into account, the investment in a hot runner system can pay off in the long run with improved production efficiency and higher quality products.

metal injection molding hot runner

On-demand Rapid Injection Molding

Sigma’s rapid tooling service helps you to have the low volume to large volume plastic parts done, with no compromise on the material selection.

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Our rapid injection molding Application

Sigma Technik Limited's rapid injection molding service injects molten plastic materials into molds using injection molding machines and molds, and cools and solidifies them over a certain period of time, ultimately forming the required plastic parts. This manufacturing process is usually suitable for producing small and medium-sized plastic parts, which can obtain high-quality and precise parts in a short period of time.

Plastic Injection Molding

Injection molding is a common manufacturing process to produce low volume to large volumes of parts typically made out of plastic. The process involves injecting molten material into a mold and letting it cool to a solid-state.

Liquid Silicone Rubber Molding

Liquid Silicone Rubber is known as LSR, which is a process used to produce parts made from silicone rubber, widely used create products such as medical devices, automotive parts, baby care products, and many others.

2K Injection molding

2K injection molding is a manufacturing process in which two different types of plastic materials are molded together in a single operation to create a single homogeneous component. This process allows for efficient and cost-effective production of high-quality parts that can perform unique functions.

Overmolding and Insert Molding

Overmolding / Insert molding combines two or more materials into a single part, one of the material is usually soft and flexible, or metal. The purpose of overmolding/insert molding is to add functionality, improve grip, provide protection, or enhance aesthetics.

Mission And Vision

Rapid injection molding materials

ABS

ABS is a type of plastic with high strength, hardness, and toughness. It has good impact resistance and wear resistance, and is suitable for manufacturing shells, components, and models.

PC

PC is a transparent, high-strength, high-temperature resistant, and excellent electrical insulation material. It is suitable for manufacturing transparent components, electronic components, and automotive components.

PP

PP is a relatively flexible material with excellent corrosion resistance and high temperature resistance. It is suitable for manufacturing containers, pipelines, baby bottles, etc.

PA

PA is a material with high strength, high rigidity, and wear resistance. It is suitable for manufacturing gears, bearings, brackets, etc.

POM

POM is a material with excellent wear resistance, toughness, and rigidity. It is suitable for manufacturing gears, bearings, pulleys, etc.

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About Us

What can we do?

Sigma Technik Limited, as a prototype production company and rapid manufacturer focusing on rapid prototyping and low volume production of plastic and metal parts, has advanced manufacturing technology, one-stop service, diversified manufacturing methods, on-demand manufacturing services and efficient manufacturing processes, which can provide customers with high-quality, efficient and customized product manufacturing services and help customers improve product quality and market competitiveness.

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Rapid Injection Molding Service Application

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Rapid Injection Molding FAQs

Burrs appear on the surface of the product, which affects its aesthetics and safety. The solution can be to adjust the parameters of the injection molding machine, such as temperature, pressure, speed, etc., or to perform post-processing, such as polishing, sandblasting, etc.

The warping deformation of the product is usually caused by unstable parameters such as temperature and pressure of the injection molding machine, or improper mold design. The solution can be to adjust parameters such as temperature and pressure, or to redesign the mold.

The occurrence of bubbles inside the product may be due to the high temperature of the injection molding machine and the high moisture content of the material. The solution can be to reduce the temperature of the injection molding machine, adjust the water content of the material, increase the pressure of the injection molding machine, etc.

The product size deviation is too large, which may be caused by material thermal expansion, mold deformation and other reasons. The solution can be to adjust parameters and optimize mold design based on material characteristics.