How to choose injection molding machine?

When we use the injection molding machine, we need to carefully understand the model and specification of the injection molding machine, because the parameters of the injection molding machine have a greater impact on the production cost, quality and efficiency of injection products. How to choose the right injection molding machine?

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1. The Selection Method of Injection Molding Machine

We should check the product specification provided by the injection molding machine manufacturer. The specification has the performance parameters of the injection molding machine, including the type of raw materials, the quality (weight) of the products, the shape design size and so on. You can sort out what kind of parameters you need, and then compare with the parameters of the injection molding machine, the value is close to the injection molding machine is worth choosing.

In addition, we also need to understand the processing accuracy, production speed and product accuracy of the injection molding machine, to see whether it meets the molding conditions of the product. In order to facilitate the mold assembly, the spacing size of the tie rod should be greater than the width and height of the mold. The size of the injection molding machine template should conform to the size requirements of the molding mold when it is installed and fixed.

2. Injection Molding Machine Operation Items

There are many operation items of injection molding machine, which can carry out the selection of injection process action, feeding action, injection pressure, injection speed, ejection type, the control of the temperature of each section of the cylinder, the adjustment of injection pressure and back pressure. Operation items of injection molding machine mainly include three aspects, that is, control keyboard operation, electrical control cabinet operation and hydraulic system operation.

3. The Molding Process of Screw Injection Molding Machine

The working principle of injection molding machine is similar to that of syringe, which is a cyclic process. Its flow is: quantitative feeding → melting plasticizing → pressure injection → filling cooling → opening and taking out parts → removing plastic parts → closing the mold → and carrying on the next cycle.

The specific steps are as follows:

1. Add granular or powdery plastic into the barrel, and process the plastic into a molten state by rotating the screw and heating the outer wall of the barrel.
2. The mold closing and injection seat forward steps, so that the nozzle is close to the mold gate passage.
3. Put the pressure oil into the injection cylinder, push the screw forward, and inject the molten material into the closed die with lower temperature at a higher pressure and faster speed.
4. Once the plastic is cured and molded, open the mold and remove the product.

Injection molding machines are divided according to structure, and there are two types to choose from. We need to make the critical decision of choosing a vertical or horizontal injection molding machine. This choice will greatly affect the efficiency and success of the manufacturing process.

Whether you're working with large, intricate parts or looking for a space-saving solution for smaller parts, this section will guide you in making the best choices to ensure you choose the right machine for your project.

What is a Vertical Injection Molding Machine?

A vertical injection molding machine is a type of industrial machinery used in the plastic molding process, where plastic resin is melted and injected into a mold to create a specific shape or form.

In a vertical configuration, the machine's mold-closing and injection assembly are aligned vertically. This design allows for the injection of plastic material into the mold from the top, making it particularly well-suited for applications with space constraints.

Vertical injection molding machines are often chosen for their smaller footprint, making them ideal for environments with limited space. These machines are commonly used for the production of smaller to medium-sized plastic components and are advantageous for insert molding applications, where pre-formed components are placed into the mold before the injection process.

The vertical orientation of these machines facilitates efficient tool changes and integration into automated production cells, providing flexibility in manufacturing processes.

Advantages of Vertical Injection Molding Machines

• Space Saving – Vertical injection molding machinery takes up half the space compared to horizontal machines used for the same functions.
• Vertical injection molding machines allow for insert or plastic-metal combined component molding.
• Gravity dislocation is eliminated due to the vertical injection machine mold alignment. Molds are aligned and supported in the vertical machine with more durability.
• Vertical clamp units are versatile and accommodate attachments.
• Automatic operation is ideal for the vertical clamp injection molding machinery without the use of an attendant.
• A wide selection of vertical clamp unit options also makes it appealing.

Disadvantages of Vertical Injection Molding Machines

• Limited Size and Weight Capacity: Vertical machines may have limitations in terms of the size and weight of the parts they can effectively mold.
• Complex Mold Design: The vertical orientation can complicate the design of certain molds, especially for intricate or large parts.
• Cycle Time: In some cases, vertical machines may have longer cycle times compared to horizontal machines, affecting overall production efficiency.
• Tooling and Equipment Costs: Tooling costs for vertical machines can be higher, especially for molds that require complex designs to accommodate the vertical injection process.

What Is a Horizontal Injection Molding Machine

Horizontal Injection Molding Machine: This is the most common type of injection molding machine. The mold clamping part and the injection part are on the same horizontal center line, and the mold is opened in the horizontal direction.

Its characteristics are a short body, easy to operate and maintain; low center of gravity of the machine, and relatively stable installation; after the product is ejected, it can automatically fall down by gravity, making it easy to realize fully automatic operation. The disadvantages are: the mold installation is troublesome, the mold may tilt or fall if the insert is released, and the machine tool occupies a large area.

Main Advantages of Horizontal Injection Molding Machines

Horizontal injection molding machines offer several key advantages that make them a popular choice for a variety of manufacturing applications:

• They can accommodate a variety of mold sizes and are suitable for producing a wide range of plastic parts, from small precision parts to larger, more complex items.
• Horizontal injection molding machines generally have higher clamping forces compared to vertical machines. This makes them ideal for molding larger, stronger plastic parts.
• Horizontal machines are very efficient for high-volume production runs. Their design allows for the integration of automated systems, helping to speed up cycle times and increase throughput.
• Horizontal configuration simplifies the process of changing molds. The mold opens and closes along the horizontal axis, allowing for quick and straightforward tool changes, minimizing downtime during production.

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Disadvantages of Horizontal Injection Molding Machines

While horizontal injection molding machines offer numerous advantages, they also come with certain disadvantages that should be considered in specific manufacturing scenarios:

• Horizontal machines generally have a larger footprint compared to vertical machines. This may be a limitation for facilities with limited floor space.
• Tooling costs for horizontal machines can be relatively high, especially for molds that require complex designs to accommodate the horizontal injection process. Initial investments in tooling can be significant.
• Although horizontal machines allow for easy access to molds, the tool changes may be slower compared to vertical machines. This can impact the overall production efficiency, especially in situations where frequent mold changes are required.
• During the injection phase, horizontal machines may require higher energy consumption compared to vertical machines. This can contribute to increased operational costs.

The Difference Between Vertical Vs Horizontal Injection Molding Machines

Feature	Vertical Injection Molding Machine	Horizontal Injection Molding Machine
Orientation	Vertical	Horizontal
Space Efficiency	Smaller footprint	Larger footprint
Versatility	Suitable for smaller parts, insert molding	Versatile for various part sizes
Clamping Force	Lower	Higher
Automation Compatibility	Compatible with automation	Highly compatible with automation
Gravity Influence	Assists in mold filling	Works against mold opening in some cases
Tool Changes	Quick and straightforward	May be slightly slower
Energy Efficiency	Can be energy-efficient	Variable, with some models optimized

Difference 1: Orientation

Vertical: In a vertical injection molding machine, the mold-closing and injection unit are aligned vertically. The injection of plastic material into the mold occurs from the top.

Horizontal: In a horizontal injection molding machine, the mold-closing and injection unit are configured horizontally, with the mold opening and closing along a horizontal axis. The injection of plastic material takes place horizontally.

Difference 2: Space Efficiency

Vertical: Vertical machines have a smaller footprint, making them suitable for environments with limited floor space.

Horizontal: Horizontal machines generally have a larger footprint, which may be a consideration for facilities with space constraints.

Difference 3: Versatility

Vertical: Vertical machines are versatile and suitable for a wide range of applications. They are often chosen for smaller parts and insert molding.

Horizontal: Horizontal machines are versatile and can handle various part sizes. They are commonly used for both small and large parts, making them suitable for a broad range of applications.

Difference 4: Clamping Force

Vertical: Vertical machines may have lower clamping force capabilities compared to horizontal machines.

Horizontal: Horizontal machines often have higher clamping force capabilities, making them suitable for molding larger and more complex parts.

Difference 5: Automation Compatibility

Vertical: Vertical machines can be integrated into automated production cells, facilitating tasks such as robotic part removal.

Horizontal: Horizontal machines are highly compatible with automation systems, making them efficient for high-volume production and automated processes.

Difference 6: Gravity Influence

Vertical: Gravity can assist in mold filling, aiding in the flow of molten plastic material. This can be advantageous for certain molding scenarios.

Horizontal: Gravity works against mold opening in a horizontal machine, which may be a consideration for specific mold designs.

Difference 7: Tool Changes

Vertical: Vertical machines often allow for quick and straightforward tool changes.

Horizontal: Horizontal machines may have slightly slower tool changes compared to vertical machines.

Difference 8: Energy Efficiency

Vertical: Vertical machines can be energy-efficient, especially during the cooling phase.

Horizontal: Energy efficiency can vary, but some horizontal machines are designed to optimize energy consumption.

Should I Choose a Vertical or Horizontal Injection Molding Machine?

The choice between a vertical and horizontal injection molding machine depends on several factors. If you are producing larger, more complex parts and have high-volume production needs, a horizontal machine might be preferable due to its higher clamping force and automation capabilities.

Horizontal machines are versatile and often suitable for a wide range of applications, offering advantages in terms of accessibility and gravity-assisted molding for larger parts.

On the other hand, if you are working with smaller parts, have limited floor space, or require insert molding capabilities, a vertical machine could be a more space-efficient and efficient choice. The decision should be based on a careful consideration of your specific production requirements, part characteristics, and available resources.

When Do We Choose a Vertical Injection Molding Machine?

When you are designing a new product, one consideration will be if your product will be best suited for vertical or horizontal injection molding. Here’s when vertical injection molding is the better choice:

• You don’t require the parts to fall from the mold for removal. Gravity will not assist parts to fall out of the open mold.
• You need concurrent operations running such as two bottom halves and one top half being used in tandem. This can allow for pre- and post-molding operations to occur while parts are being filled inside the mold.
• Your parts require insert or over molding to enhance the product function and/or visual appeal. Inserts used for insert molding will be held in place by gravity, which makes the operation easier to incorporate.
• Your part design and molding operation requires more consistent resin flow inside the mold and more accurate temperature distribution.
• Your operation requires a smaller injection molding machine that takes up less floor space. Vertical injection molding machines are typically half the size of horizontal machines concerning square footage.
• Your design requires less pressure and clamping force. Gravity will assist to keep the molds together during the injection molding operation.

When Do We Choose a Horizontal Injection Molding Machine?

Horizontal injection molding has been the more common choice since injection molding began, but that doesn’t make it the clear winner.  It is more common, and the injection molding machines are utilized more in the molding industry, which may make it easier to find a turnkey supplier for your design.  These are times when it is the better choice for your molding operations.

• You need to utilize a manual part removal operation from the mold via human operator or a robotic arm. Horizontal molds can be the better choice for this.  Gravity can also help the parts to fall out of the mold.
• You need to make multiple parts for every molding cycle with multiple part cavities in the mold.
• Your part, or some design features, are cylindrical shaped.
• You need a high number of parts in a production run.
• Your part design does not require insert or over molding.

Conclusion

In short, the horizontal injection molding machine is more suitable for large-scale production lines. On the contrary, you can use it to make a variety of things at home because it is easy to install and operate if you want to make a lot of molds with different shapes. So, I believe that it will give you a better effect with the horizontal injection molding machine.

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