plastic
raw materialAlthough prices fluctuate, cost control is a long-term compulsory course for injection molding enterprises. The material cost accounts for 50-60% of the total injection molding cost, which is the largest single expenditure and a priority focus for cost reduction. The true cost control lies in the system optimization during the production process——
Large quantity, saving a little bit on each individual item, accumulating small gains. How to "carve out" the key few grams on each product without sacrificing product functionality and mass production stability?
The three paths of microcellular foaming, sandwich injection molding, and thin-walled high-speed injection molding correspond to the three directions of reduction, substitution, and acceleration, respectively.Each path has its own applicable boundaries, so careful selection and comprehensive accounting are necessary.
Three paths to smart material selection
Less materials, use the right materials, and use materials more efficiently
To this end, Zhenxiong provides three core solutions around injection molding, production cost reduction, and production management.
01
Less materials used
Micro foaming injection molding process, structural substitution of some materials
Inject supercritical nitrogen or carbon dioxide into the molten resin, and then
moldMicro scale closed cell structures are formed inside the mold cavity, occupying space with gas to achieve a certain degree of weight reduction while meeting specific product performance requirements. This is not simple foaming, but precise structural reshaping.
Cross sectional view of microcellular injection molded products
● Product weight reduction10%～12%；
● Reduced demand for locking force30%；
● Average reduction in product costs10%～20%.
In response to the requirements of injection, mold locking, and process control for micro foaming technology, Zhenxiong can provide corresponding two board machine forming solutions. In the automotive parts industry,Adopting precise clamping force control technology to ensure the dimensional stability of automotive interior parts, reduce product deformation, and maintain a product qualification rate of over 98%，Truly achieving 'weight loss without compromising quality'. This process has been widely implemented in fields such as 3C electronics, medical, home appliances, and automotive parts.
02
Using the right materials
Sandwich injection molding process, allowing different materials to perform their respective duties
Sandwich injection molding adopts a structure of "skin layer+core layer", and different materials are injected layer by layer through co injection technology: raw materials are used for positions that require quality and surface performance, while lower cost materials or recycled materials can be used internally according to product requirements.
Analysis diagram of sandwich injection molded products
● Core layer can be added20%～50%Recycling materials；
●Load bearing performance retention rateOver 95%；
The qualified rate of finished products is as high asOver 96%.
The Zhenxiong two plate backpack hybrid multi material injection molding machine is equipped with dual electric injection units, which can control the injection sequence and proportion of different materials according to specific process requirements, providing equipment foundation for sandwich structure forming. Taking daily storage boxes as an example, the proportion of recycled materials in the core layer can reach 20%, and the surface is still smooth and tidy, with no compromise on load-bearing performance. Sandwich injection molding is more suitable for enterprises with stable sources of recycled materials and product structure and appearance requirements that allow for the use of sandwich solutions. The other side of material control is actually material allocation. Allowing different materials to perform functions that match their costs is itself a form of manufacturing efficiency.
03
More efficient use of materials
Thin walled high-speed injection molding, combining "material saving" and "efficiency"
In large-scale production scenarios such as packaging and thin-walled containers, it is not just how much material is used for a single product that truly determines cost competitiveness. It also depends on how many pieces can be produced stably in an hour. The logic of thin-walled high-speed injection molding is not only "thin", but also to improve unit time output through high-speed injection and shorter molding cycles.
Schematic diagram of thin-walled high-speed injection molded products
● Weight reduction of non appearance parts12%～18%；
● Shortened production time for individual items20；
● Reduction in unit production costs by approximately15%～20%.
震雄SUPER
PACK high-speed packaging injection molding machine,
Specially designed for thin-walled packaging, with a maximum injection speed of 500mm/s,SUPER PACK produces 12 aviation cups in 5 seconds and integrates automatic palletizing and packaging lines, from raw materials to finished products in one go. Thin walled high-speed injection molding puts material utilization efficiency and production efficiency on the same cost table. More suitable for production scenarios such as packaging containers with larger order sizes and higher levels of product standardization.
There is no simple "who is better" among the three processes
They solve different problems
The final suitable process route naturally varies depending on the product structure, material requirements, order size, and existing equipment conditions. There is no "optimal process" that deviates from production conditions, only cost reduction solutions that are more compatible with actual manufacturing scenarios.
Smart Material Selection
Starting from precise selection
There is no absolute superiority or inferiority among the three processes, only whether they match or notProduct structure, order size, and equipment capability.
Zhenxiong has always been committed to providing suitable injection molding solutions for every manufacturing enterprise - whether it is microcellular foaming, sandwich injection molding, or high-speed thin-walled injection molding, we have formed a mature process platform. We not only deliver equipment, but also deliver cost reduction paths that can be mass-produced,Accompanying Zhenxiong, making materials smarter and manufacturing more effortless.
This article is reproduced from a third-party platform for the purpose of promoting information exchange and has no profit-making purpose. The views expressed in this article are not related to the position of this website, and unverified information is for reference only and is not used as any investment or trading basis. If you have no intention of infringing on media or personal intellectual property rights, please call or write to us, and our website will handle it as soon as possible.
