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Shortcut to Superfast Consistent Quality Injection Molding


We all want to supply Quality products to our customers. But sometimes we end-up sacrificing a lot of production time and wasting raw material by rejecting what is coming out of the molding machine. This is done either because the parts do not meet the drawing specifications or they are failing the Visual inspection criteria. And sometimes parts look great and they are dimensionally correct but trouble happens when we try assembling them, they will not fit.

As you all would agree, faster a product is made, the cheaper it would cost in terms of labor, overheads and everything. Longer it takes to make a product, especially due to quality issues, the cost per piece increases. Every rejected part reduces the profit per piece. Also, if you are regrinding and reusing the rejects then regrind cost adds up and also causes wastage of raw material.

More often than not, the above problem lays with the raw material Melt flow Index (MFI) and Injection molding Process settings.

Just an analogy for you, if you go to a 5 Star/high end Restaurant and order a Biryani today, and go there again after a month, you will find that the Biryani tastes the same, it even looks the same. The reason for the Biryani taste being the same every time is “Recipe”. The Chef has a checklist, he uses the same recipe every time where he takes the same amount of rice, same amount of water, boils it to the same temperature, ensuring it by using a thermometer; also boiling the rice for the same time, measuring time with a stopwatch. He would also add other ingredients and spices which are measured with a measuring spoon, and same amount would be added every time. He will not have a +/- 5% on the ingredients and spices, or the taste of biryani would change.

In order to make a perfect injection molded shot every time, like the Biryani, we have to create a molding recipe. There are 30 different Ingredients (parameters) that need to be determined using “Real Art of Molding” or RAM techniques. This would ensure that your process is repeatable and same amount of plastic is injected every shot. Also it ensures that the plastic properties are also same every shot. If the quantity and the properties of the molten plastic every shot is the same, then the quality will also be the same every shot. Also, changes in the MFI of the incoming raw material will not affect the molding process because RAM will take care of it. Once RAM is used, your process will be robust enough to ensure same quality product every time it’s molded, be it today, after a month or after a year. RAM helps achieve cavity-to-cavity consistency, shot-to-shot consistency and run-to-run consistency.

We can implement RAM for you. We can also train your engineers. RAM training entails learning the process of making the perfect recipe for a perfect molded part. We train you how to determine each of the 30 ingredients of a molding recipe on an Injection molding machine. We teach you the theory and also make you do it hands-on on the injection molding machine.

It is our goal and mission to transform the way Injection molding is done in India. We want every injection molder to make quality parts and never have to worry about common molding defects like Flash, Splay, Warpage, Short shot, Shrinkage, Sink marks and Rejects due to new lot of material. And this is possible by implementing RAM and doing a RAM window. So let’s start molding the right way, the best way, let’s RAM

We have 20+ years of worldwide experience in Plastic injection molding/Insert molding and LSR (Liquid Silicone Rubber) molding, Metal Injection Molding (MIM), commencement of new plants, performing validations (IQ, OQ, PQ) per GMP Guidelines for medical devices. We help create new products from concept Ideas, manufacture, assemble and supply. We have trained several companies on Real Art of Molding (RAM) which has improved productivity and yield in Injection molding. We hold two US Patents and have published research papers in Journals and Magazines.

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