Injection Molding - Thermoplastic Resins
Stack Plastics uses thermoplastic resins exclusively in our injection moulding processes. Thermoplastics are ideal injection molding resins, as they are easily moldable when softened by heat, and harden to their original strength during the cooling process. Thanks to their molecular makeup, these resins can be softened by heat over and over again, making them easily reusable and recyclable.
Because they can be formed and moulded into nearly any shape, thermoplastic resins are ideal materials for injection moulding. With Stack Plastics' engineering consultation services for customer designs and the expertise of our mold- and toolmakers, we can create virtually any part or component your project requires. We will work with you to ensure that your finished parts match your exact specifications.
What Are Thermoplastic Resins?
Thermoplastic resins are plastic materials that become easily moldable when heated above a specific temperature, and solidify as they cool back to ambient temperature. In general, thermoplastic resins have a high molecular weight; the intermolecular forces joining their polymer chains weaken quickly as temperature increases, turning the material into a viscous liquid. This makes thermoplastic resins ideal for injection molding, as the heated materials will flow readily into the mold under pressure to fill the entire cavity, even in molds with complex geometries.
The Right Injection Moulding Resin for Your Project
There are a number of thermoplastic resins available, and Stack Plastics works with a wide variety of them in our injection molding processes. Common injection moulding thermoplastics include:
Polyether ether ketone exhibits superb mechanical properties, including high hardness, strength, and stiffness, as well as high chemical and thermal degradation resistance. PEEK is easy to machine and fabricate, and highly resistant to pressurized water and steam. Ideal for medical device components.
Ultem provides greater strength and dimensional stability than most thermoplastic materials, and maintains its strength and stiffness at temperatures up to 200°C (392°F). It is also highly resistant to alcohols, acids, solvents, and other harsh chemicals, as well as environmental stresses and cracking.
Polycarbonates (PCs) are tough, strong thermoplastics that provide high stiffness and impact strength, good thermal resistance, and excellent strength retention at high temperatures. It exhibits high tensile, shear, and flexural strength, excellent creep resistance, and good dielectric properties, among other beneficial characteristics.
Also known as thermoplastic rubber, TPR is a class of copolymer materials that combine certain physical characteristics of plastic and rubber. TPR materials exhibit high flexural fatigue, weathering, and chemical resistance, high impact strength, good tear and abrasion resistance, and good dielectric properties.
When used in injection molding, acrylonitrile butadiene styrene provides very high toughness, impact strength, tensile strength, and stiffness. It offers good machinability, and maintains dimensional stability under load. ABS is highly resistant to head, acids, alkalis, and most oils, with excellent ductility and creep resistance.
This unique family of thermoplastic resins exhibits high dimensional stability and rigidity, good dielectric performance, and reliably constant mechanical properties. They are uniformly lightweight, with a high strength-to-weight ratio. Styrenics are water resistant and provide excellent thermal insulation.
Liquid crystal polymer maintains high mechanical strength at high temperatures, exhibits extreme chemical resistance, and is inherently flame retardant. LCP offers good weatherability and high resistance to stress cracking. This exotic injection molding resin is also known as Kevlar, Vectra, and Zenite.
The term “thermoplastic elastomer” encompasses six classes of thermoplastic resins, all of which provide superior consistency and energy efficiency. TPEs require little to no compounding, and no stabilizers, cure systems, or reinforcing agents. Stack Plastics can help you determine which type of TPE is best for your injection molding project.
Olefins are polymer-blend materials that combine a thermoplastic, an elastomer or rubber, and a filler material. This diverse group of materials can exhibit a wide range of properties based on their components, but, in general, olefins provide high stiffness, high impact and UV resistance, excellent dimensional stability, good flexibility, and excellent weather resistance.
We also work with an array of custom blends, should your project require a material with unique characteristics. Our expert team will work with you to determine the ideal resin for your needs.
Injection Molding with Carbon Fiber Additives
Carbon fiber can be added to most of the thermoplastic resins we work with to increase the resin’s strength and durability. Molding with carbon fiber can often improve a thermoplastic’s other properties, as well.
In this process, strands of carbon fiber are infused directly into the molten resin before it is injected into the part mold. The resulting materials are collectively known as carbon fiber reinforced plastics, or CFRPs. CFRP components are becoming more and more common as replacements for metal parts in new product designs. Injection molding with carbon fiber can create parts that are nearly as strong as steel and weigh significantly less.
The Injection Molding Experts
Stack Plastics has a long history of excellence in working with thermoplastics. Whether your project requires injection molding polycarbonate, injection molding PEEK, ABS, Ultem, or any other thermoplastic resin material, we are your number one source for high quality, precision moldings.
Contact Stack Plastics for further details on our thermoplastic resin injection moulding.