Injection moulding

How does injection moulding work?

1. Mould design and fabrication

• The injection moulding process begins with the design and fabrication of the mould. Moulds are typically made from durable metals like aluminium or steel and are precision-machined to match the detailed features of the intended product. Using advanced CAD software, our engineers meticulously design the mould to ensure it captures every detail and dimension required.
• Single and multi-cavity moulds: Depending on your production needs, we cancreate single or multi-cavity moulds. Single-cavity moulds produce one part per cycle,whereas multi-cavity moulds can produce multiple identical parts simultaneously,significantly increasing production efficiency.

2. Material preparation

• Once the mould is ready, the next step involves preparing the material. The chosen material is fed into a heated barrel where it is melted. The heating process involves the use of heating bands and a helical screw that mixes the material to ensure it reaches a consistent molten state.
• Material selection: We work with a wide range of materials, including thermoplastics (like polyethylene, polypropylene, and ABS), elastomers, metals, and more. Each material offers unique properties, allowing us to select the best option for your specific application.

3. Injection and forming

• The molten material is then injected into the mould cavity under high pressure. This pressure ensures that the material fills every part of the mould, capturing the intricate details and complex geometries of the design. The mould is cooled to solidify the material, forming the final part.
• High precision and consistency: Our injection moulding machines are equipped with precise controls to maintain consistent temperature and pressure, ensuring uniformity and quality in every part produced.

4. Cooling and ejection

• After the material has solidified, the mould is opened, and ejector pins push the finished part out. The cooling process can be optimised using cooling lines that circulate water or oil, reducing cycle times and enhancing efficiency.
• Trimming and finishing: Excess material, known as flash, is trimmed off, and additional post-processing steps such as painting, coating, or assembly may be performed to meet your specific requirements.

Benefits of our injection moulding services

High production efficiency

Our streamlined injection moulding process allows for rapid production of large volumes of parts, making it ideal for mass production scenarios. The high level of automation minimises human intervention, reducing the likelihood of errors and increasing efficiency.

Precision and uniformity

We deliver parts with exceptional precision and consistency, ensuring each piece meets your exact specifications. Our advanced equipment and stringent quality control measures guarantee that every part is manufactured to the highest standards.

Versatile Material Options

We offer a wide selection of materials to suit various applications, from general-purpose plastics to high-performance engineering polymers. This versatility enables us to meet the specific needs of different industries and applications.

Complex part geometries

Our sophisticated moulding capabilities allow us to produce parts with intricate details and complex geometries. Whether you need components with tight tolerances, complex shapes, or fine details, we have the expertise to deliver.

Why choose KB Components?

Customer-focused solutions

We prioritise understanding of your needs and deliver customised solutions that exceed your expectations. Our dedicated customer service team is always available to assist you with any inquiries or concerns.