Injection molding machines are widely used in manufacturing industries to produce kinds of products, from automotive parts to consumer goods. These machines melt and inject molten material into a mold to form a solid object. The injection molding process is highly versatile and efficient, making it an essential tool for modern manufacturing.
Choosing the right injection molding machine for a specific application is critical to achieving the desired production output and product quality. Factors such as material type, production volume, and budget must be considered when selecting a machine. Additionally, the brand and model of the machine can significantly impact the manufacturing process and product outcomes.
We will explore the universe of the injection molding machine and discover the various types available, working principles, advancements, and more in this article. We’ll also provide a comprehensive overview of the major brands in the market, including their unique features, strengths, and weaknesses. Upon finishing this article, you will have a deeper understanding of the various types of injection molding machines on the market and be equipped with the knowledge to select the optimal one that aligns with your manufacturing requirements.
Working principle of an injection molding machine
An injection molding machine works by melting plastic granules or pellets and then injecting them into a mold under high pressure. The machine consists of several main components, including the hopper, the barrel, the screw, the nozzle, the mold, the clamping unit, and the hydraulic system.
The process begins with the plastic granules being fed into the hopper, which then feeds them into the barrel. Inside the barrel, the plastic granules are heated and melted by the turning screw. The screw also pushes the melted plastic forward and then injects it through the nozzle into the mold cavity.
The clamping unit holds the mold closed, which applies high pressure to keep the mold securely shut during the injection process. Once the plastic has been injected into the mold, it is allowed to cool and solidify, after which the mold is opened, and the finished part is ejected.
The hydraulic system provides the necessary power to operate the machine’s various components, including the clamping unit and the screw. It is also responsible for regulating the process’s pressure, speed, and temperature, ensuring that the plastic is melted and injected into the mold consistently and accurately.
Types of injection molding machines
Hydraulic Injection Molding Machine
A hydraulic injection molding machine uses hydraulic pressure to operate the machine. The hydraulic system consists of a hydraulic pump, a motor, a hydraulic cylinder, and valves. The hydraulic pump supplies high-pressure hydraulic oil to the hydraulic cylinder, which then drives the screw to inject molten plastic into the mold cavity. These machines are popular due to their ability to provide high clamping force and the flexibility of the hydraulic system. They are commonly used in industries where the production volume is high, and the cost of production is not a significant concern.
Electric Injection Molding Machine
An electric injection molding machine uses an electric motor to operate the machine. These machines are more energy-efficient than hydraulic machines because they don’t require the use of hydraulic oil. Instead, they use electric motors to drive the screw, injecting molten plastic into the mold. Electric machines are known for their high precision, repeatability, and speed. They are ideal for producing small to medium-sized parts with high accuracy and consistency.
Hybrid Injection Molding Machine
A hybrid injection molding machine combines the advantages of hydraulic and electric machines. They use hydraulic systems for clamping force and electric systems for the injection process. These machines are energy-efficient and provide high precision, speed, and flexibility. They are commonly used in industries where a high level of precision and accuracy is required.
Two-Shot Injection Molding Machine
A two-shot injection molding machine is a type of machine that can produce two different types of plastic parts in one cycle. It has two injection units that can inject different types of plastic material into the mold simultaneously. This machine is ideal for producing complex parts with different colors, materials, or textures.
Multi-Shot Injection Molding Machine
A multi-shot injection molding machine is a type of machine that can produce multiple parts in one cycle. It has multiple injection units that can inject different types of plastic material into the mold. This machine is ideal for producing complex parts with different colors or materials.
Vertical Injection Molding Machine
A vertical injection molding machine has a vertical clamping unit and an injection unit that is mounted vertically. This machine is ideal for producing parts with inserts or overmolding. It is commonly used in industries where space is limited.
Gas Injection Molding Machine
A gas injection molding machine is a type of machine that uses gas to assist in the injection molding process. The gas is injected into the mold cavity to help the plastic material fill the mold. This machine is ideal for producing parts with a hollow center or requiring high dimensional accuracy.
Liquid Silicone Injection Molding Machine
A liquid silicone injection molding machine is a type of machine that is used to produce silicone parts. The machine injects liquid silicone into the mold cavity, which is then cured to form a solid part. This machine is ideal for producing parts with high heat resistance, durability, and biocompatibility.
Micro Injection Molding Machine
A micro-injection molding machine is a type of machine that is used to produce small and precise parts. Injection molding machines are known for their exceptional accuracy and repeatability, which make them the preferred choice for manufacturing parts with intricate geometries and precise tolerances. They are widely used in a range of industries, including electronics and medical devices.
Powder Injection Molding Machine
A powder injection molding machine is a type of machine that is used to produce parts from metal or ceramic powders. The powders are mixed with a binder and injected into the mold cavity. After the part is formed using a specialized injection molding process, it is sintered to remove the binder and fuse the powders. This results in part with high strength and complex geometries. The powder injection molding machine is an excellent option for producing such parts and is widely used in industries such as aerospace and automotive.
Parts of an injection molding machine
An injection molding machine is composed of several parts that work together to produce a molded product. The key components of an injection molding machine include the following:
Injection unit
The injection unit is the heart of the injection molding machine. It is responsible for melting and injecting the plastic material into the mold. The injection unit comprises the hopper, screw, barrel, and nozzle.
The hopper is where the raw plastic material is loaded into the machine. Typically, a funnel-shaped container feeds the plastic pellets into the screw. The screw then conveys the plastic pellets through the barrel, where they are heated and melted. Heating elements heat the barrel, and the screw is rotated by a motor, pushing the plastic material forward.
Once the plastic material is melted, it is injected into the mold through the nozzle, which is located at the end of the barrel. The nozzle forms a seal with the mold and injects the melted plastic into the mold under high pressure. The injection unit is designed to be precise and repeatable, as even small variations in temperature or pressure can affect the quality of the final product.
Clamping Unit
The clamping unit is an essential part of an injection molding machine that holds the mold in place during the injection process. The clamping unit consists of a stationary platen and a movable platen that holds the mold. The two plates are held together by a mechanism such as a toggle, hydraulic cylinder, or electric motor. The clamping force is generated by this mechanism and is necessary to keep the mold closed during the injection process.
The size of the clamping unit is determined by the maximum size of the mold that can be used. The clamping force is also an important factor and depends on the material being molded, the size of the part, and the required precision of the molded part. A larger clamping force is needed for materials with higher melting temperatures, and larger parts require more clamping force to prevent deformation.
The clamping unit also includes a mold height adjustment mechanism that precisely adjusts the mold height to accommodate different molds. This adjustment is necessary to ensure that the mold closes properly and that the injection molding process is successful.
Control Unit
The control unit is the brain of an injection molding machine. It is responsible for managing and coordinating the various processes that occur during the injection molding process. The control unit allows the operator to set and monitor critical parameters such as temperature, pressure, and cycle times. In modern machines, the control unit is typically a computerized system that uses a graphical user interface (GUI) to display information and allow the operator to interact with the machine.
The control unit also contains safety features such as emergency stop buttons, safety interlocks, and alarms that alert the operator to potential problems or issues. The control unit may also have diagnostic functions that can detect and identify problems with the machine or the molding process.
Advanced control units may include features such as real-time monitoring, data logging, and predictive maintenance capabilities. These features can help improve process efficiency, reduce downtime, and minimize the risk of defects or production issues. Some machines may also be equipped with remote monitoring capabilities, allowing operators to monitor and control the machine remotely using a computer or mobile device.
Hydraulic Unit
The hydraulic unit is a key component of hydraulic injection molding machines. It comprises a hydraulic pump, motor, oil tank, oil filter, and other hydraulic components. The hydraulic unit is responsible for generating the hydraulic pressure needed to operate the injection molding machine.
The hydraulic pump provides the hydraulic pressure, and the hydraulic motor converts the mechanical energy into pressure. The hydraulic pressure is used to power the clamping unit and the machine’s injection unit. The machine’s control system controls the hydraulic unit, which adjusts the hydraulic pressure and flow rate based on the molding process requirements.
One of the main advantages of hydraulic injection molding machines is their high power and pressure capabilities. Hydraulic units can generate much higher clamping forces than other types of injection molding machines. However, hydraulic machines can also be less energy-efficient than electric or hybrid machines due to the energy required to power the hydraulic system.
Hydraulic units are commonly used in large-scale manufacturing applications, such as automotive parts, appliance components, and industrial products. Hydraulic injection molding machines are known for their reliability, long service life, and low maintenance costs, making them a popular choice for many manufacturers.
Electrical Unit
The electrical unit of an injection molding machine is responsible for controlling and coordinating the movement and operation of the machine. It comprises various electrical components and systems that work together to ensure the safe and efficient operation of the machine.
One of the key components of the electrical unit is the motor, which provides the power to operate the machine’s hydraulic and mechanical systems. The motor is controlled by a series of electrical circuits and switches that allow for precise control over the speed and direction of the machine’s movements.
In addition to the motor, the electrical unit also includes a number of sensors and feedback systems that help to monitor the machine’s operation and ensure that it is functioning correctly. These sensors may include temperature, pressure, and position sensors, among others.
Finally, the electrical unit also includes the machine’s control panel, which sets and adjusts various machine settings, such as temperature, pressure, and cycle time. The control panel may include a touchscreen interface and various switches, dials, and other controls for adjusting the machine’s operation.
Injection Molding Machine Brands Worldwide
Major Injection Molding Machine Brands
Injection molding machines have revolutionized the manufacturing industry, making it easy to produce complex and intricate plastic products. As the demand for high-quality plastic products increases, so does the need for reliable and efficient injection molding machines. Let’s explore the major injection molding machine brands worldwide, categorized by country of origin. These brands have established a reputation for producing high-performance machines that meet the needs of manufacturers across various industries.
| Japan | Germany | USA | China | Taiwan | Italy | Switzerland |
| Sumitomo | Arburg | Husky | Chen Hsong | Victor Taichung | Negri Bossi | Netstal |
| JSW | KraussMaffei | Milacron | Haitian | FCS | ||
| Toyo | Wittmann Battenfeld | Negri Bossi | Yizumi | Multiplas | ||
| Nissei | Engel | Jon Wai | ||||
| Mitsubishi | Demag | |||||
| Fanuc | Netstal | |||||
| Toshiba | Billion SAS | |||||
| Sodick | ||||||
| Kawaguchi |
Top 10 Injection Molding Machine Brands
Husky
Husky Injection Molding Systems is a leading supplier of injection molding equipment and services to the plastics industry. Founded in 1953, Husky has become a global leader in injection molding systems, with sales and service facilities in more than 40 countries. Husky has a global market share of over 15% in the injection molding industry.
Husky offers a broad range of injection molding machines, hot runners, and molds and is known for its high-speed packaging and medical molding systems. The company strongly focuses on innovation, with a large team of engineers and scientists dedicated to developing new technologies and products.
Major production models:
- HyPET HPP5e: High-performance injection molding system for PET preforms.
- Hylectric H3000: Hybrid injection molding system for a wide range of applications.
- Schöttli 32-cavity mold: Precision mold for medical and packaging applications.
- Ultra H3000: High-speed injection molding system for thin-walled packaging.
KraussMaffei
KraussMaffei, a renowned manufacturer of injection molding machines, extrusion equipment, and automation systems, has been a key player in the plastic processing industry since its establishment in 1838. Headquartered in Germany, the company has since grown to become a leading global supplier of plastic processing equipment. With a focus on innovation, KraussMaffei is committed to delivering high-quality, efficient, and reliable machines to meet the diverse needs of its customers. The company has gained a reputation for manufacturing high-performance machines with advanced technology and innovative features, which have made them a popular choice for many industries.KraussMaffei has a global market share of over 10% in the injection molding industry.
KraussMaffei’s injection molding machines are known for their high precision and speed, with models available for a wide range of applications. The company offers a broad range of machines, from small and medium-sized machines for precision parts to large machines for automotive and packaging applications.
Major production models:
- CX 160-750: High-performance injection molding system for automotive and packaging applications.
- GX 650: Two-platen injection molding system for high precision and productivity.
- MX 850: Hybrid injection molding system for a wide range of applications.
- PX 320-2000: High-performance injection molding system for thin-walled packaging.
Netstal
Netstal is a Swiss manufacturer of high-precision injection molding machines and automation systems. The company was founded in 1868 and has since become a global leader in injection molding technology, with sales and service facilities in over 50 countries. Netstal has a global market share of over 5% in the injection molding industry.
Netstal’s injection molding machines are known for their high performance, reliability, and energy efficiency, with models available for various applications. The company offers a broad range of machines, from small and medium-sized machines for precision parts to large machines for automotive and packaging applications.
Major production models:
- ELION 1750: High-performance injection molding system for a wide range of applications.
- EVOS 3500: Hybrid injection molding system for high precision and productivity.
- PET-Line 2400-4000R: Injection molding system for PET preforms.
- SynErgy 1750: Injection molding system for high-performance applications.
Arburg
Arburg is a German-based company that was founded in 1923. They specialize in manufacturing injection molding machines and offer a range of machines suitable for various applications.
Arburg is a well-known name in the injection molding industry, and the company has a global presence with subsidiaries and representative offices in over 100 countries. The company’s revenue in 2020 was around €720 million.
Arburg offers a range of injection molding machines, including vertical, horizontal, electric, and hybrid machines. Some of their major production models include the Allrounder, a versatile machine suitable for a wide range of applications, and the Freeformer, a machine designed for additive manufacturing. Arburg machines feature advanced control systems, high-performance hydraulics, and energy-efficient drives.
Major production models:
- Allrounder 370 S: Injection molding system for precision parts.
- Freeformer 200-3X: Additive manufacturing system for functional parts and prototypes.
- Multilift V: Robotic automation system for injection molding machines.
- SELOGICA: Control system for injection molding machines.
Demag
Demag is a German-based company that was founded in 1902. They manufacture a range of products, including injection molding machines, cranes, and drives.
Demag has a strong global presence, with subsidiaries and representative offices in over 50 countries. The company’s revenue in 2020 was around €570 million.
Demag offers a range of injection molding machines, including hydraulic, electric, and hybrid machines. Some of their major production models include the IntElect, which is an electric machine with high precision and energy efficiency, and the El-Exis, which is a hybrid machine suitable for high-speed applications. Demag machines feature advanced control systems, high-performance hydraulics, and energy-efficient drives.
Major production models:
- EL-Exis SP: High-performance injection molding system for a wide range of applications.
- Systec SP: Hybrid injection molding system for high precision and productivity.
- IntElect: Injection molding system for precision parts.
- Ergotech: Injection molding system for a wide range of applications.
Engel
Engel is an Austrian-based company that was founded in 1945. They specialize in the manufacturing of injection molding machines and automation solutions.
Engel is a well-known name in the injection molding industry, and the company has a global presence with subsidiaries and representative offices in over 60 countries. The company’s revenue in 2020 was around €1.3 billion.
Engel is a well-known name in the injection molding industry, and the company has a global presence with subsidiaries and representative offices in over 60 countries. The company’s revenue in 2020 was around €1.3 billion.
Major production models:
- e-mac: Hybrid injection molding system for a wide range of applications.
- duo: Two-platen injection molding system for high precision and productivity.
- victory: Injection molding system for a wide range of applications.
- viper: Robotic automation system for
WittmannBattenfeld
Wittmann Battenfeld GmbH is a company that was formed by merging two leading manufacturers of injection molding machines, robots, and peripheral equipment, namely Wittmann and Battenfeld. The company is headquartered in Kottingbrunn, Austria, and has production plants in several countries worldwide. It strongly focuses on sustainability and energy efficiency, with all of its production sites powered by green electricity.
According to a report by Market.us, WittmannBattenfeld holds a market share of approximately 4.4% in the global injection molding machine market. Production Models: WittmannBattenfeld offers a wide range of injection molding machines with clamping forces ranging from 30 to 6000 tons. Some of its popular models include SmartPower, MacroPower, and EcoPower.
WittmannBattenfeld machines are known for their energy efficiency, precision, and user-friendliness. The SmartPower series, for example, boasts a highly dynamic drive system that reduces energy consumption by up to 60% compared to conventional machines.
Major production models:
- SmartPower
- MacroPower
- MicroPower
- EcoPower Xpress
- Vertical R Series
Sumitomo
Sumitomo Heavy Industries Ltd. is a Japanese company that was founded in 1888. It has diverse business operations, including industrial machinery, shipbuilding, and environmental systems. Its injection molding machinery division, Sumitomo (SHI) Demag Plastics Machinery GmbH, is based in Germany and has production sites worldwide.
According to a report by Market.us, Sumitomo holds a market share of approximately 3.3% in the global injection molding machine market. Production Models: Sumitomo offers a range of electric, hybrid, and hydraulic injection molding machines with clamping forces ranging from 8 to 5600 tons. Some of its popular models include the SE-DUZ and SE-HSZ series.
Sumitomo’s machines are known for their precision and energy efficiency. Its SE-HSZ series, for example, features a highly rigid clamping system and a high-performance injection unit that enables precise molding of high-quality parts.
Major production models:
- SE-HSZ Series
- SE-HDZ Series
- SED-CI Series
- SDI Series
- SE-DUZ Series
Fanuc
Fanuc Corporation is a Japanese company that was founded in 1956. It specializes in robotics, CNC systems, and factory automation systems. Its injection molding machinery division, Fanuc Roboshot, is based in Japan and has production sites in several countries worldwide.
According to a report by Market.us, Fanuc holds a market share of approximately 3.1% in the global injection molding machine market. Production Models: Fanuc offers a range of electric and hybrid injection molding machines with clamping forces ranging from 30 to 300 tons. Its Roboshot series is a popular choice for precision molding applications.
Fanuc’s machines are known for their high precision, speed, and reliability. Its Roboshot series features a patented injection unit design, ensuring accurate and repeatable molding.
Major production models:
- Roboshot Alpha-SiA series
- Roboshot S-2000i series
- Roboshot S-2000i-B series
- Roboshot S-2000i-B-Servo series
- Roboshot S-2000i-B-Servo Alpha
Milacron
Milacron Holdings Corp. is an American company that was founded in 1860. It specializes in plastics processing technologies, including injection molding, extrusion, and blow molding. It has production sites in several countries worldwide.
According to a report by Market.us, Milacron holds a market share of approximately 2.9% in the global injection molding machine market.
Milacron offers a range of electric, hydraulic, and hybrid injection molding machines with clamping forces ranging from 55 to 6100 tons. Some of its popular models include the Elektron, Magna, and Maxima series.
Major production models:
- Magna T Servo
- Magna V Servo
- Magna Toggle Servo
- Magna Vertical
- Maxima Servo
Price of Different Brands
The price of different brands of injection molding machines can vary widely depending on the brand, the model, the size, and the features of the machine. Generally speaking, higher-end brands such as Engel, KraussMaffei, and Husky are more expensive than lower-end brands such as Borch and Haitian.
According to a report by Persistence Market Research, the average price of an injection molding machine was around $15,000-$25,000 in 2017. However, prices can range from as low as $1,000 for a small, basic machine to as high as $300,000 or more for a large, high-end machine.
The price of an injection molding machine can be influenced by various factors, such as the level of automation, machine quality and durability, and the level of customer support and service provided by the manufacturer. It’s important to consider these factors when choosing the right machine for your specific manufacturing needs, as they can impact the long-term cost-effectiveness and overall efficiency of your production process. It’s important to consider not only the upfront cost of the machine but also the long-term operating costs and maintenance requirements when choosing a machine.
Advancements In The Injection Molding Machine
Injection molding machines have come a long way since their invention in the 19th century. Advancements in technology have improved the accuracy, efficiency, and versatility of these machines. Here are some of the key advancements in injection molding machines:
Electric Injection Molding Machines
One of the major advancements in injection molding machines is the development of electric injection molding machines. These machines use electric motors instead of hydraulic systems to power the machine. Electric machines offer greater precision, energy efficiency, and faster cycle times than hydraulic machines.
Servo-Driven Injection Molding Machines
Another major advancement in injection molding machines is the development of servo-driven machines. These machines use servo motors instead of hydraulic systems to power the machine. Servo-driven machines offer greater precision and energy efficiency than hydraulic machines.
Computer Control
The development of computer control has greatly improved the accuracy and consistency of injection molding machines. Computer control allows for precise control of temperature, pressure, and speed, which results in more consistent parts.
Automated Material Handling
Another important advancement in injection molding machines is the development of automated material handling. Automated material handling systems allow for faster and more efficient production by automatically moving raw materials and finished parts in and out of the machine.
Industry 4.0 Integration
The latest advancement in injection molding machines is the integration of Industry 4.0 technologies. This includes using sensors and data analysis to monitor and optimize machine performance, as well as integrating the machine with other systems in the manufacturing process for greater efficiency and productivity.
Conclusion
In conclusion, injection molding machines have become integral to modern manufacturing processes. Thanks to technological advancements, they have evolved over the years to become more efficient, reliable, and versatile. The market for injection molding machines is highly competitive, with various brands and types of machines available to choose from. It is important to choose a machine that best suits your needs and budget.
Overall, injection molding machines offer a cost-effective and efficient way to produce high-quality plastic products on a large scale. With the advancements in technology and the introduction of new materials and processes, the future of injection molding looks promising. As the demand for plastic products continues to increase, injection molding machines will likely remain a vital component of the manufacturing industry for many years.
Thank you for reading! I’m Ray Liu, an injection molding industry expert with over 10 years of experience. If you found this article useful, please share it with your friends. If you have any questions about the injection molding process, feel free to contact me. I’m always happy to assist you.
