Figuring out the injection molding machine size for a part has been covered in Three Considerations to Determine Injection Molding Machine Size. Most of the time, the clamp tonnage required to keep the mold closed during plastic injection is the key factor that dictates press size. Traditionally processors have attacked clamp tonnage using higher flow materials, increasing wall thickness, shortening length of flow and specifying larger gate sizes. Now there is another bullet in the holster; iMFLUX constant low pressure molding.
In a conventional injection molding process, high injection speeds transfer to pack and hold when the cavity is approximately 95% full. High injection speeds translate into high plastic pressure as shown by the blue curve in the figure below. The higher the plastic pressure, the more tonnage is needed from the machine clamp. In contrast, the iMFLUX process is injected at a low constant pressure represented by the green curve in the figure below. As a result, much lower plastic pressure is being exerted to the mold reducing clamp tonnage. Studies comparing conventional molding and the iMFLUX process using multiple types of materials (ABS, ABS+PC, PA66, PA66-30GF, PC, and PP) have shown a 55%-65% reduction in clamp tonnage.
The ability to run molds in smaller tonnage presses outfitted with the iMFLUX process represents another competitive advantage for AGS Technology and an added cost saving benefit for its customers.