Injection Moulding

The process of injecting plastic material...

The process of injecting plastic material into a mould cavity where it cools and hardens to the configuration of the cavity is best used to mass produce highly accurate and often complex 3D end use parts. Injection moulding is a recognised production technology usually associated with high production volumes and long lead-times. However, since early 2000 there has been an increasing supply of 'rapid tools', (some produced using additive technologies and others machined from aluminium and steel). Whilst some of these tools have the potential to meet production quantities, their primary focus is high volume prototyping. That means Injection Moulding can now be considered as a prototyping solution with the potential to also address early production requirements. The greatest upside to using this process is that it delivers the production intent material and, once the tooling is in place, parts are available quickly and at low cost.

Whale 3D's state of the art manufacturing facility uses the latest injection moulding equipment encompassing the latest software for process set-up and repeatability.

Integrity of components is ensured by our team of expert moulding and setting specialists who run Advanced injection moulding machines including Demag and Sandretto models ranging from 30 to 200 tonne capacity. Components are produced at the tightest tolerances and accuaracy levels using 100% virgin materials. Our moulidng facility runs a 24 hours run capacity.

The cost and time of tooling moulds is often compounded by design mistakes that require the mould to be re-made or the need to create multiple iterations before the final post design and quality are achieved. Whale has therefore embraced the use of 3D printed moulds to create functional IM prototypes.

Polyjet injection moulds are not intended to be replacements for hard or soft tools used in mid and high volume production. Rather they are intended to fill the gap between soft tool moulds and 3D printed prototypes.

Polyjet 3D printed moulds allows manufacturers the ability to take functional testing to a new level by creating product prototypes from the same IM process and materials that will be used to create the final product. This allows companies to generate superior perfomace data and validate certification confidence.

Polyjet moulds are unique in that they perform in the same way as metal molds but are a fraction of the cost and faster to make, thereby allowing manufacturers to easily evaluate performance fit and quality of potential products before mass production starts.

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