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Heat staking is another permanent bonding technique. This bonding concept takes advantage of the base material being malleable plastic. The base material is heated up and the plastic reformed using a combination of heat and pressure to model the plastic around the second piece forming a hardware-free bond. One advantage is that we can use it to combine two alike or dissimilar materials. Also, it is a reasonably easy bonding process that does not require any additional parts or materials.
The automotive industry is controlling fuel efficiency by switching to lightweight plastics. Using plastics for many auto parts reduces the vehicle’s overall weight and increases fuel efficiency. With the need for better fuel economy solutions, the automotive business has turned to plastics manufacturing for many automotive components. Additionally, government regulations recently are pressing the automotive industry to move from iron and steel to plastics. This push from the government is shifting the automotive industry towards higher-grade plastics in place of metals. The recent drive for a plastic manufacturing process in the automotive segment allows us to anticipate that injection molded plastics will increase rapidly under these new regulations.
Electronics are still a leading sector in the use of plastic resin parts. Plastics do not conduct electricity. Electronics often need plastics to insulate the electricity running through them. Consequently, a plastic part can make the perfect insulator for electronics and electrical devices. Plastics also have a lower conductivity for heat. Meaning, that plastics do not transfer heat well due to their insulating properties. This particular property works to the advantage of the plastics industry when it wishes to shield heat from other more delicate parts or the user. You may also treat plastics with special flame retardant finishing applications to further support their fire-resistant properties.
Tapping and threading make for easy disassembly. Both processes produce threads on a part. “Threads” means a small threadlike ridge or groove. Tapping and threading both create threaded surfaces. The threading process makes threads on the outside surface. Like a bolt or screw, for example. Similarly, tapping creates threads inside a hole, such as a nut. Threading is performed with a die tool, while tapping uses a tapping tool. When opposite features come together, the threads interlock.
View some of Integrated Molding Solution’s plastic manufacturing projects that feature tapping or thread cutting.
Insert molding is a systematic process of modeling thermoplastic material around an additional component. Most pliable thermoplastic resins are suitable for the insert molding process. The added piece is often a metal part. The main advantage of mold-in inserts is that generic threaded inserts are readily available in standard sizes. Generic inserts help keep costs down and avoid further customization costs. Metal inserts provide properties that plastic alone wears down over time, such as threading.
View some of Integrated Molding Solution’s plastic manufacturing projects that feature molded-in inserts.
These two forms of painting apply color to the part. The painting application is ideal after molding. Painting can be any color or even metallic finishes painted over plastic. This application also helps with particular requirements such as non-static parts. In comparison, pad printing permanently places an image onto the components. Pad printing is similar in nature to a rubber stamp. An inverted image is coated with paint and laid against the part to transfer the image to the part’s surface.
View some of Integrated Molding Solution’s plastic manufacturing projects that feature painting or pad printing.
Electroplating or electro-deposition is a process whereby a metal material coats the surface of a part. In the electroplating process, a permanent bond connects the metal to the surface of another piece. The process involves an electrolyte or plating bath charged with electricity. The electricity-charged bath deposits small particles of the metal over the part’s surface. Therefore, this process effectively coats the plastic piece in a completely shiny, smooth metal finish.
Plastics are a growing industry that is becoming prominent in the healthcare sector. The medical industry is establishing a foothold in plastic 3D printing as a modern solution. Plastic molds help doctors to see a CT scan in 3D physically. The dental occupation often uses 3D plastic molds to custom fit parts before surgery. Research suggests that Medical grade polymers used in healthcare will positively impact growth in the medical field over the next decade.
Adhesive and solvent bondings are irreversible processes and do not permit disassembly. Adhesive applications use a bonding material that chemically combines two plastic pieces for a permanent bond. Conversely, solvent welding is a liquid solution that softens the plastic’s properties. As the solvent dries, it binds the two individual parts together permanently as one. Adhesives and solvents are often lighter, less expensive, and faster to assemble than mechanical fasteners.
Mechanical fasteners have the distinct advantage of offering disassembly and reassembly. Components include screws, nuts, bolts, rivets, pins, and inserts are examples of mechanical fasteners. Tapping is a process used to place threading inside a plastic injection molded hole. Advantages mechanical fasteners provide are a stronger, longer-lasting bond, durability, and disassembly. When you need to ensure the strength of the hold, mechanical fasteners are likely the correct choice.
Ultraviolet (UV) bonding is another permanent bonding process. The ultraviolet bonding process carries the advantage of bonding plastics to other materials such as glass, ceramic, and metal. Bonding using ultraviolet light is a highly intense concentration of ultraviolet lighting that instantly dries or cures the adhesive. Moreover, UV bonding works in seconds to bond plastic components with other materials. A solid bond forming in moments lessens production time and often reduces rates.
