Flashless Molding
Flashless molding a manufacturing process used in the production of rubber or plastic components without forming excess material on its surface. It is also known as clean molding which means it does not require trimming to remove excess flash on the surface of the formed mold.
Advantage of Flashless Molding Process
Flashless molding process has various advantages and here are some of them;
The elimination of extra work of trimming the excess material from the mold helps to minimize material waste, saves time and reduces labor cost needed.
Flashless molding reduces mold damage caused by the flash which can affect the mold over time. This process increases the mold life and reduces maintenance needed.
Complex shapes can be designed without any worry of flash formation on the mold using this process. The freedom in designing enhances functional and innovative product design.
The elimination of extra work of removal of excess material, results in increased output rate and productivity.
How Flashless Molding Works
Mold is carefully prepared by ensuring it is clean and favorable condition before it is closed by bringing together the two halves of the mold. Next, you will inject the molten material into the mold. Usually, the conditions must be necessary to ensure material fills the mold.
That is, the process should take place under recommended pressure and temperature.
The mold has venting channels that allow trapped air to escape during the injection process. After the cavity is filled, cooling process begins by solidifying. By the end of the process, the molten material will conform to the mold’s shape.
Factors to Consider for Successful Flashless Molding Process
Mold Design – The mold should be well designed to minimize gaps to ensure proper venting and including features such us shut-off surfaces to prevent formation of excess material.
Material Type – Choosing the right material is of importance when using flashless molding process. The material should have low shrinkage to minimize the risk of flash formation and also high dimensional stability.
Gate Design and Placement – The entry point of the molten material into the mold needs to be optimized to allow smooth flow.
Molding parameters – Molding parameters consisting of temperature, cooling time, pressure and injection speed, requires quality control to ensure proper outcome.
Monitoring the Process – Monitoring the mold process is important to detect any deflection that may lead to formation of flash.
Applications of Flashless Molding
Electronics and Electrical Equipment – Flashless molding is used in production of electrical items like switches, housing, connectors, and other components used in electronics. This allows proper functioning of the parts since they require clean finish and precise dimensions.
Aerospace and Defense – There are some of the aerospace and defense require parts with complex shapes and important performance requirements. Parts that can be manufactured through flashless molding in this sector are: gaskets, small rubber or plastic parts for aircraft, defense systems and satellites.
Medical Devices – In medical industries, flashless molding is needed to design medical devices and components because they require precisions and cleanliness. Examples of medical items made through this are surgical instruments, syringes, seals and connectors
Automotive Industry – Flashless molding is used for production of components like seals, small rubber parts and gaskets in automotive industries. Flashless molding is is an ideal choice for manufacturing this parts because they require a high level of precision and tight tolerance.
Consumer goods – Consumer goods like house hold items, kitchenware and toys are manufactured through flashless molding. The exception of flash, a high level of aesthetic and functionality can be achieved in the products.
Best Material to use in Flashless Molding
It is commonly used material for flashless molding having good chemical resistance, low moisture absorption and toughness
Polypropylene is known for its low density, high chemical resistance and excellent mechanical properties.
It is also a good thermoplastic used for flashless molding that has dimensional stability, strength and impact resistance.
Epoxy resin is known for heat resistance, electrical insulation and chemical resistance properties
Phenolic Resins offer a good heat resistance, dimensional stability and flame retardancy properties
Engineering plastic are materials that are also used in flashless molding that helps to increase chemical, mechanical and thermal properties. Example of this type of plastic include Nylon, Polycarbonate, Polyoxymethylene, etc.