Achieved the elimination of warping and deformation with our independently developed IMM method, creating reliable parts without variation between shots.
The elimination of warpage and deformation in plastic molded products is an eternal theme. One of the advantages of plastic molding technology is the freedom of shapes that can be molded, but this can lead to warpage and deformation. Particularly, once a mold has been created, the countermeasures are limited, resulting in defects that trouble manufacturers. **Main Causes of Warpage** - Uneven mold temperature: Molds are operated at temperatures lower than the melting resin temperature to cool and solidify the molten resin. At this mold temperature, partial temperature differences occur due to the product shape and component structure. This disrupts the cooling balance of the parts, resulting in deformation during demolding. - Flow direction during injection: In injection molding, the shrinkage rate may differ between the flow direction and the perpendicular direction. This is particularly evident in fiber-reinforced resins. The unevenness of this shrinkage leads to warpage and deformation. - Uneven filling pressure: When injecting the molten resin into the mold, the filling pressure can be uneven. For example, the pressure is high near the gate, while it is lower on the opposite side of the gate. Additionally, areas with thin product thickness experience higher pressure, while thicker areas have lower pressure.
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These three factors intertwine complexly, leading to warping and deformation. To resolve this issue at a higher dimension, a very high level of technical skill is required. Specifically: - Product design technology By utilizing simulations to tune the shape to one that is less prone to warping and deformation, and by adjusting the overall rigidity and wall thickness of the parts, we can eliminate warping and deformation. - Mold design technology By predicting areas prone to warping and deformation through simulations, we can enhance cooling efficiency and creatively arrange the layout of the components to anticipate warping, thus resolving the issue. - Uneven filling pressure relief technology By meticulously setting the gate positions and using the IMM method to compress areas with insufficient filling pressure, we can create a uniform filling pressure and eliminate warping and deformation. Our company can implement comprehensive measures to suppress warping and deformation. We will address this as part of our resin parts design support services.
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We, PLAMO Co., Ltd., have continued to pursue the theme of how to embody the "ideal form" of plastic molded products based on product design technology, mold technology, and injection molding technology with superior cost performance. The unique molding technologies born from the fusion of this orientation and foundational technologies demonstrate their true value as groundbreaking methods that overturn the common sense of plastic molding, leaving no room for others to follow. In the fiercely competitive world of manufacturing, PLAMO continues to challenge itself as a plastic molding manufacturer capable of providing solutions rooted in the creation of new technologies that respond promptly to the needs of the next generation.
