ISO 13485

Scientific Injection Molding Techniques


    At All-Plastics, our Master Molders provide enhanced injection molding through Scientific Molding techniques. Our techniques improve quality, consistency, while optimizing efficiency and performance. Providing high quality products is our #1 priority and we will take every precaution in guaranteeing all products meet all requirements.

    Consistent & Robust Processes Improve Quality & Speed to Market

    We have invested in state-of-the-art technology designed to limit the amount of variation inherited in the processing of injection molding plastic componentry. We have created the ability to truly mold components that cycle constraints are limited to the part geometry.

    ABILITY TO FOOL PROOF PROCESSES TO ENSURE ZERO DEFECTS Systematic methodology to process development that can reduce part quality variations.

    Accuracy of +/- 25 Microns


    RJG eDART Quality Molding

    RJG eDART systems are used extensively throughout our plants and we are assured quality parts shot after shot with real time process control. The eDART system allows us to control the entire plastic injection molding process and pinpoint, diagnose and resolve problems faster throughout the molding process.

    • Automatically sort parts using meaningful process alarms
    • Individual part traceability for every cycle
    RJG Training facility with Master Molders on Staff

    As an intricate part of the RJG technology, cavity pressure sensing technology allows All-Plastics to produce superior quality products through precise injection molding capabilities. Cavity pressure technology utilizes a number of sensors throughout the molding process in order to determine optimum results in the qualification process.

    • Relative Viscosity: determines optimum fill rate to reduce inconsistencies
    • Cavity Balance: determines if cavities are properly filled
    • Gate Seal Analysis: packs the same amount of plastic from shot to shot

    What is Scientific Injection Molding?

    Not familiar with Scientific Injection Molding?

    Scientific Injection Molding (SIM), also known as Decoupled Injection Molding, is a systematic approach to molding in which the fill, pack and hold stages are treated separately to minimize fluctuations while improving product consistency. 

    Unlike traditional injection molding, SIM relies on controlled, data-driven processes. It accepts the scientific principle of plastic behavior and combines them with known variables we can control to reduce cycle times and increase machine efficiency.

    Advantages of a Decoupled Process


    Quantitative Measurables

    Scientific Molding minimizes start-up and cycle times while reducing scrap. It also streamlines problem-solving and process consistency, boosting profitability and efficiency.


    Consistent Process Development

    With Scientific Molding, process development and troubleshooting methods are standardized across technicians, presses, molds and companies, ensuring consistent, effective practices.


    Machine-Independent Processes

    Scientific Molding focuses on material behavior, allowing for machine-independent processes. This flexibility reduces the need for machine-specific parameters.


    Fool-Proof Quality Assurance

    Scientific Molding guarantees consistent part quality regardless of machine, material or mold variations, enhancing product reliability and customer satisfaction.

    Factors Involved in Scientific Molding


    Types of Materials

    Scientific molding uses a wide range of materials, each chosen based on specific requirements and desired final product characteristics. These include the following:


    • Thermoplastics like polyethylene (PE), polypropylene (PP) and polystyrene (PS) are famed for their excellent recyclability and flowability and are commonly used in scientific molding processes.
    • Thermosetting Plastics (Thermosets) like epoxy resins, polyurethane (PU) and bakelit offer exceptional heat resistance and dimensional stability, making them ideal for applications where exposure to high temperatures is a constant factor.


    Material Characteristics

    Material properties such as melt temperature, melt flow rate, thermal conductivity and viscosity are critical factors in SIM. These properties affect how the material behaves during the molding process, which influences the final product’s quality and consistency.


    With these considerations in mind, the choice of material is crucial to the success of scientific molding as it directly impacts the final product’s properties. Some material characteristics to consider include the following:


    • Melt Flow Index (MFI): This measures a material’s flowability when melted, which is vital for filling complex molds evenly.
    • Tensile Strength: Indicates a material’s ability to withstand pulling forces without breaking.
    • Impact Strength: Reflects a material’s resistance to sudden impacts or shocks.
    • Heat Resistance: Determines the material’s ability to withstand elevated temperatures without deforming or degrading.
    • Chemical Compatibility: Ensures the material is suitable for the intended environment and will not react with surrounding substances.


    Material Characterization

    Before beginning the molding process, materials undergo thorough characterization. This involves testing and analyzing properties like molecular weight distribution, rheological behavior, and thermal properties, ensuring precise control and predictability during molding.


    The following are reasons why material characterization is essential in scientific molding:


    • Precise Material Selection: Material characterization enables engineers to select the most suitable polymer for a given application, considering characteristics like tensile strength, melt flow index and heat resistance.
    • Optimal Processing Conditions: By studying rheological behavior, engineers can design precise injection profiles that ensure uniform mold filling, reducing defects and minimizing the need for post-processing.
    • Consistency: Material characterization establishes a baseline for material properties, ensuring that each batch behaves consistently. This consistency is essential for producing uniform products across production runs.
    • Predictability: Armed with detailed material data, engineers can predict how a material will behave under different processing conditions, allowing for accurate process design and optimization.
    • Reduced Waste: Precise material characterization minimizes the likelihood of errors or defects, reducing material waste and saving costs.


    Process Documentation

    Accurate documentation is a fundamental aspect of scientific molding. It involves the meticulous record-keeping of all process parameters like temperature, pressure, cycle time and cooling rates to ensure repeatability and traceability in production.


    Beyond continuously monitoring relevant process parameters, process documentation offers other invaluable benefits. For instance, adopting a data-driven approach supports ongoing process optimization, which helps manufacturers fine-tune their operations for improved efficiency and product quality over time. 


    Machine Calibration

    In highly controlled processes like scientific molding, slight deviations can lead to defects or inconsistencies in the final products. To eliminate or minimize these deviations, injection molding machines are calibrated to maintain precision and consistency. 


    During calibration, engineers carefully set and continually monitor all production variables to ensure the machine operates within the specified parameters, minimizing the likelihood of deviations.


    Once calibrated, the injection machine serves as a reliable workhorse, capable of precisely replicating the ideal conditions identified during the setup phase, ultimately contributing to the cost-effectiveness and reliability of the entire manufacturing process.


    Role of Software in the Scientific Molding Process


    The role of software in Scientific Injection Molding (SIM) is instrumental in elevating the precision, efficiency, and overall performance of the manufacturing process. Advanced software solutions help ensure the success of injection molding projects as they enable more precise control and quicker response to deviations, further improving the molding process:


    • Real-time Data Analysis: Software continuously collects sensor data, including temperature, pressure, injection speed, and material flow. It promptly evaluates this data to monitor the ongoing process.
    • Predictive Modeling: Beyond data analysis, these tools use advanced algorithms to anticipate potential process deviations, foreseeing issues before they cause defects or delays.
    • Immediate Feedback and Control: Software detects deviations and instantly adjusts the process. For example, if temperature strays from the target, it modifies heating or cooling systems, maintaining consistency.
    • Process Optimization: Simulation and modeling tools assist engineers in refining the process before production. They virtually test parameters and materials, reducing trial-and-error on the shop floor.
    • Data Visualization: Software offers clear data visualization through charts, graphs, and dashboards, simplifying real-time monitoring and decision-making.
    • Historical Data Analysis: SIM software stores historical data, which is valuable for trend analysis, process improvement, and quality assurance. Engineers use past performance to inform decisions.
    • Remote Monitoring and Control: Many SIM software packages enable remote process oversight and adjustment, aiding troubleshooting and real-time modifications, even during off-hours.


    Industries That Benefit from Scientific Molding


    • Medical: Precision and reliability are paramount in producing medical devices and components.
    • Automotive: Complex parts require consistent quality and structural integrity.
    • Electronics: Tiny, intricate components demand precision and consistency.
    • Consumer Products: Maintaining high-quality standards in consumer goods production.
    • Aerospace: Critical components demand precision and reliability.
    • Packaging: Efficient and precise molding is vital for cost-effective packaging solutions.

    Telecommunications: Precision molding supports the production of high-performance equipment.

    Advantages of a Decoupled Process Request a Quote

    • Quantitive measurables: minimize start up times, cycle times, root cause problem solving, scrap and process inconsistencies while maximizing efficiencies and profitability.
    • Process development and method of solving problems consistent between technicians, presses, molds and companies.
    • Independent process sheets regardless of machine type (toggle, hydraulic, electric, etc.) because process is developed by “what the plastic feels” as opposed to machine inputs.
    • Fool-proofing your process to guarantee consistent quality of a molded part regardless of machine, material or mold inconsistencies.