Injection Moulding

Injection moulding is the process of injecting molten thermoplastic polymer into a cavity, in a hardened steel mould tool, which opens on a split line (following rapid cooling) to reveal a plastic moulding. Typically this process is used to produce plastic mouldings where the relatively high tooling cost can be justified by low unit costs and tolerances which cannot be achieved by other moulding processes.

aki specialise in the production of demanding customer products which may require any combination of: close tolerances, aesthetic external finish and engineering polymers coloured to a matched specification.

Many of the mould tools we run in our moulding machines have complex cores which operate in a plane 90 degrees to the tool opening plane. This enables designers to incorporate under-cuts and other complex features in their designs thereby eliminating or simplifying secondary assembly operations.

Our current machine line-up ranges from 6 tonne to 450 tonne clamp force. All of our machines are microprocessor controlled and capable of exacting tolerances with a high level of repeatability.

Automated de-moulding from the press (robots) are used extensively to maintain the consistency of the moulding cycle. Manual removal of mouldings from the press may vary the cycle and, thereby, introduce a variable which may affect quality.

We process all engineering polymers including: ABS, Polyesters, Polysulphone, Polycarbonate blends.

The two impression Kohler Mira handset is a good example of a moulding which is produced using most of the features mentioned above. The highly complex tool has retracting cores and produces mouldings to close tolerances as well as a very highly polished surface finish. The mouldings are removed from the press by an automated handling system. aki operate a range of computer controlled machines varying in size from 6 to 450-tonnes, many with robotic product removal for improved consistency. The latest Oima 250-ton machine is fitted with a Battenfeld gas injection unit. This can be used for production of hollow components with internal cavities and also to reduce sink marks in thick walled mouldings.

Injection Moulding Products include:

  • Shower components
  • Extraction systems
  • Speaker housings
  • Fan blades
  • Laboratory products
  • Aircraft undercarriage components
  • Medical laryngeal mask components

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