Product designers need to consider the materials used for their product or their component parts. This can make a major difference when it comes to your final product. Two of the common manufacturing processes are cast and injection molding. So, what’s the difference? Below you will find helpful information to guide you as you consider which type of molding is right for your product or component part.
Cast vs Injection Molding
Both cast and injection molding have differences that play an important role in the manufacturing process. Both need to be considered when making design decisions for your product or component part. The cast molding process uses the force of gravity to inject the material into your mold. However, the injection molding process is different as it uses high pressure while your material is in a liquid state during the process. In order to determine which type of molding is right for you, consider the following differences between cast and injection molding.
Costs Related to Manufacturing and Tooling:
Tooling can be more expensive with injection molding due to the high pressure and temperature associated with the process. Tooling in injection molding can include closed metal molds that require complex systems. The complex systems are necessary to regulate the temperature and material flow. In addition, the molds require costly machining and finishing steps. On the other hand, cast molding uses simpler mold tooling, which results in lower costs. Cast molding can include open molds, close molds, compression molds, and many other designs. This allows you more flexibility when designing your mold.
Compatibility with Your Materials:
Both cast and injection molding are optimized based on the materials you will be using. Because injection molding uses high pressure with your materials in a liquid state, the materials you use need to have low viscosity. The low viscosity materials allow the material to take shape due to the unique nature of the injection method. Some of the common materials include polypropylene, polyethylene, ABS, and TPU. Cast molding most often uses thermoset materials as they are irreversibly shaped when the material cures. Thermoset materials have a much wider range of durometers, better resistance to abrasion, and enhanced chemical resistance as compared to other materials. Based on this, it is clear that the type of materials you use will indicate the type of molding that will be optimal for your product or component part.
Prototypes:
The type of molding you use also relies on how quickly you want a prototype. Getting your prototype quickly, cost-effectively, and efficiently is likely a necessary factor for your business. The faster you get the product on the market, the faster you can increase profits and recuperate product development costs. Injection molding, as discussed, is more complex. This can result in higher costs and more time in terms of production. However, cast molding offers more flexibility and can generally be made faster. Another factor when it comes to your prototypes is how confident you are in your vision. You may need to make a number of molds to achieve your desired result. Consider your timeline and budget before you make a final decision about the type of mold.
The original article was featured Real Seal's website.
For more information about injection molding or cast molding, reach out to Gallagher Fluid Seals today.