INSTRUMENTATION • ELECTRONICS
The pros of plastic INJECTION MOULDING
Katie Reed from BEC dives into the world of fi lter manufacturing to explore how injection moulding solves several industry problems
F
iltration devices are commonly implemented across automotive, bio- medical, marine and domestic
appliances, keeping air and water clean, and machinery and appliances functioning smoothly. In industry, the quality and cost of each fi lter is vital, and injection moulding provides an ideal manufacturing method that keeps costs low and quality high.
THE INJECTION MOULDING FILTRATION PROCESS Injection moulded fi lter parts begin life as a 3D CAD drawing. Optimised for injection mould tooling, these become the guide for creating the mould tool. Designing out high-cost areas such as non-uniform draft angles, undercuts and inserts at the design stage reduces timescales and additional costs for toolmaking. Next, material selection is crucial
to the longevity and properties of the part, as well as the quality and price. Available materials for both the mesh and the encapsulation framework are wide ranging in origin, application, and cost. Steel and plastic mesh, recycled content, environmental resilience and tensile strength can all be incorporated into injection moulded fi lters. Bespoke depth-media, woven and
non-woven meshes can be fabricated for fi lters to provide exactly the level and types of fi ltration required to ensure their longevity. Nylon is often selected over other engineering plastics owing to its strength and chemical resistance, ensuring that the tough environment’s fi lters endure. A Moldfl ow analysis simulates the
material fi lling the part, allowing for potential quality issues such as weld lines, sinkage or shrinkage to be rectifi ed. Once the design is agreed, a steel tool is produced. Robotically or
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Injection moulding allows for signifi cant cost savings
manually, a fi lter mesh is loaded onto the core of the mould tool, the tool closes and clamps around the mesh, and molten plastic is injected through a sprue. The plastic fl ows through into the mould tool, surrounding the mesh. After a swift cooling process, the tool separates and the fi lter is ejected from the tool, to be trimmed or undergo further assembly.
THE BENEFITS OF INJECTION MOULDED FILTERS Once made, a steel mould tool can produce up to millions of identical fi lter mouldings. This high-volume repeatability and precision help ensure that fi lter manufacturer’s products are made to a high quality. Stringent inspection, testing and documentation throughout the manufacturing process ensure these are maintained. Aside from the initial cost of tooling,
injection moulded fi lters present a very low cost-per-part solution. In particular, for large-scale production, this cost- per-part decreases even further.
Any waste plastic or rejected
mouldings used in injection moulding fi lter production can be re-ground for recycling or immediate use. Injection moulding machines are increasingly energy eff iciency, particularly hybrid and all-electric models. Katie Reed from Bec says: “Injection
moulding as a fi lter manufacturing process allows for cost savings (particularly at scale), while it incorporates fl exibility over design and material selection. Repeatability and strict control of process variables ensure tight quality control.”
For more information visit:
www.becgroup.com
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