Mark Adams
Many different processes are available to make injection molding parts, as molding of plastic products has always been essential for the traditional injection molding process. We found in some cases, it is possible to save money and time using a rapid injection molding process. Rapid injection molding is the quicker version, but the same as conventional injection molding used to churn out the injection molding products in a short time frame to meet customers’ needs. This process is often used in conjunction with prototype injection molding.
While producing parts quickly, the companies use rapid injection molding, which is proved to be a production bridge that incorporates a rapid tooling method to deliver production-grade injection molding parts quickly. Rapid tooling can be used to develop innovative products in a shorter time.
RIM comes with excellent production speed and exceptional strength by using CAD mold tooling. RIM uses different materials for its dies that can be redesigned easily.
RIM starts with the models of CAD materials that are sent directly where the molding process begins, often forged in aluminum. With the help of an electric discharge machine(EDM), it modifies molding features like edges and corners that allow more cast-affecting tooling. Some other applications that RIM offers are following
- Testing different materials
- Implementation of bridge tooling
- Repeats with rapidly build prototypes
- Testing functions during the product development process
- Demand volatility management
- Produce thousands of products within days
- Holds low-volume production for on-demand parts
Rapid injection molding is the best choice for your plastic project as it offers rapid tooling in a shorter processing time than other prototyping techniques. For the best production of plastic parts, you need to consider some factors cautiously.
Firstly, the Tool structure or design of the part is an essential factor while performing all injection molding processes, including rapid injection molding. Part size intricacies are time-consuming and need to be reduced. The best way to overcome this problem is to break the big complex into smaller parts in a shorter time, which is possible only by adopting the rapid injection molding technique.
Secondly, part material contributes a lot to the production process. Therefore, to take better advantage of the quicker RIM, you need to choose the readily available materials and use them in a proper time while the mold is being prepared.
Thirdly, you need to analyze the costs of the materials used in the rapid molding process. If you want to produce parts quickly, it will increase the costs. Therefore, you should strike a balance between speed and cost for the best results.
RIM cannot shorten all processes, although it accesses all the efforts and resources. So it needs to ensure that all the processes are done efficiently without wasting time. There are some advantages of using rapid injection molding for plastic parts.
- Using EDM, RIM provides the best surface finishing that sharpens the inner corner and edges.
- It provides great and limited mold precision as high as IT7.
- The production in thermoplastic resins in 2-5 weeks as compared to other prototyping techniques.
- Most colors and materials are available in different shapes.
- Production tooling molds can be used for large batches to execute up to 100,000 products.
- The molds are made of aluminum instead of steel that have remarkable universality.
- Intricate and consistent parts are designed using CNC machining.
Moreover, RIM resins are usually chemical resistant that provide services to users without health and safety problems. Using this process, you can produce thousands of parts with suitable materials, colors and designs that can be textured easily. Having all these reliabilities, rapid injection molding produces affordable and straightforward plastic components in a short time.
Following are the Prototyping techniques that have benefits that are not found in other production processes.
- Strength and flexibility
- Surface finish
- Almost zero material waste
- Outstanding precision
- Quick lead time
Strength And Flexibility
RIM ensures flexible ejection angles and strength of walls by injecting liquid resin into the cavity under high pressure. It also ensures the parts are without pores, and the material is best and most flexible. RIM balanced the strength and flexibility with a single resin material.
Surface Finish
CNC milling and some finishing operations perform the surface finishing of the molded parts that are managed in rapid injection molding. One of the most widespread is polishing, and EDM is used to cut and sharpen the edges of the cavity at the size of 0.8mcm.
Almost Zero Material Waste
RIM injects only the required amount of materials into the cavity compared to other prototype techniques such as 3D printing. After the molding processes, the waste materials like sprue, runners, gates, and flash can be recycled and reused.
Outstanding Precision
Rapid injection molding offers an outstanding precision of parts that allows greater accuracy of the materials over other manufacturing techniques. The mold precision of RIM can be as high as IT7 as compared to 3D printing, which offers the best precision IT9.
RIM ensures flexible ejection angles and strength of walls by injecting liquid resin into the cavity under high pressure.
Quick Lead Time
The primary and important benefit that RIM offers is the quick lead time of the molding parts that research and engineers like for each batch in a short period. CNC machining and aluminum make the molding process quick and accessible in just 2 or 3 weeks.
Conclusion
Rapid injection molding is the same as conventional molding but works quickly. RIM resins are usually chemical resistant that provides services to users without health and safety problems. Using this process, you can produce thousands of parts with suitable materials, colors, and designs textured easily. Having all these reliabilities, rapid injection molding produces simple and affordable plastic components in a short time.
