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All About Automotive Injection Molding

by Ameli
Automotive Injection Molding

Injection molding is amongst the standard means of production for plastics items. It is suitable as it provides various solutions for producing an intense amount of high-quality injection automotive parts from a wide range of polymers. There is an increased need for safety, consistency, and quality in the automotive sector, as these hold extreme significance in the business. Automotive plastic injection molding is amongst the essential factors for manufacturing.

We will be discussing automotive plastic injection molding and its various uses in the automotive industry. Different automotive injection molding companies are known for providing and manufacturing extensive parts for the automotive industry.

History Of Automotive Plastic Injection Molding

During the old times of the automotive industry, the production of cars solely depended on metal. In other words, they were heavy and clunky. However, as the sector grasped the technology and advanced, the plastics market emerged during the 50s. With the emergence of the plastic market, companies began to experiment with plastic car parts in their production.

During the 70s, manufacturers developed and released their very first car with plastic décor. In the 80s, they also began to add more functional parts such as bumpers, fenders, and plastic headlights.

In the early 2000s, automotive manufacturers invented the first plastic structural car components. These car components had the advantage of being lighter than their classic metal counterparts, which unlocked the potential for fuel efficiency and a cheaper production rate. Today, injection molding is now the dominant production way for manufacturing plastic cars in the automotive industry.

Uses Of Automotive Injection Molding

In the automotive industry, injection molding is among the most effective methods manufacturers use to produce plastic parts. However, due to the massive number of parts production, covering all parts will not be possible. Let us look at the primary car parts made with automotive injection mold.

Under-Hood-Components

For the last twenty years, many under-the-hood components that the manufacturers used to make were from metals and now have shifted to plastic. For these applications, solid polymers such as Nylon, ABS, and PET are common. 

However, manufacturers can now make parts such as head covers for cylinder and oil pans with the help of injection molding. It offers light weights and is more cost-effective than metal parts.

Car Exteriors

Injection molding is a good process for most of the exterior components of the car, such as fenders, bumpers, door panels, floor rails, light housing, etc. Splash guards can be used as the best example for proving the durability of the injection molded parts. Additionally, the components protecting the cars from debris and reducing splashing are usually rubber or other flexible materials.

Car Interior

Manufacturers are also known for producing various automotive interior parts with automotive injection molding. The parts it helps to make are instrumentation components, surfaces, dashboards, faceplates, interior surfaces, door handles, air vents, glove compartments, etc. 

In addition, they are also used for producing decorative elements made of plastic. This process has opened doors for various innovations. Companies can now make beautiful interior designs for vehicles and provide them with a luxurious and beautiful look.

Overmolding

It is another plastic injection molding process used in the automotive sector for combining two different materials in one item. This process puts one type of material over the other type for creating the final part. It allows the manufacturers to create complicated items that may contact different surfaces at the same time. 

The process of overmolding usually comprises soft thermoplastic materials such as urethanes and thermoplastic elastomers. This process is best for many of the pieces that are within the cabin of the car. 

Most of the injection molding parts come in contact with people, which offers a pleasing sensation to the touch, making the difference between a car feeling well made and luxurious or cheap.

Insert Molding

It is a plastic injection molding process popular in the automotive industry which lets the metal or ceramic inserts such as nuts, screws, bushings, or metal filters. These are directly molded into the piece. 

The ceramic or metal parts will be placed in the mold, and melted plastic will then be injected within the mold to create a seamless piece of two different materials. Insert molding is a creative way for reducing weight and the use of costly materials such as metal. 

Rather than making the entire metal piece, only the connecting pieces can be made of metal, while the other materials are good to go if made of plastic.

Alternative To Injection Molding

In most cases, molded plastics worked as an alternative to metals. Before, manufacturers made items such as brackets, seatbelt modules, airbag containers exclusively from metal. In today’s time, it is one of the most preferred methods for these plastics.

Whereas manufacturers may sometimes replace the molded parts of the plastic with the 3D printed parts. It happened specifically in prototyping, where there is no excessive need for intense durability or smooth surface. 

Most of the moldable plastics work as FDM 3D printer filaments or SLS 3D printers for nylons. Some high-tech 3D printers are also able to print reinforced composites for more durable parts.

3D printing is a cost-effective alternative for injection molding, especially for non-mechanical parts. Because there is no need for the tools, the cost of tools is less, which makes 3D printing cost-effective.

In some cases, companies may also use 3D printing for a handful of end-use automotive parts. Companies can also use SLM 3D printing for the production of fluid handling components such as valves. However, another option that companies use is SLS 3D printing to produce parts such as trim and windbreakers. These are usually made with injection molding.

Manufacturers can also use additive manufacturing for the broader range of injection molding parts in the future. It may range from body panels to powertrain parts.

Conclusion

This is all the information about the injection molding process for the automotive industry. Technology has made so many things easy for us human beings; there are still many innovations that may be about to come that will shape the future of automotive productions. Injection molding is one of the oldest manufacturing processes, which helps significantly in this modern times.

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