Discover how overmoulding in injection moulding, product design, and industrial design can enhance your product development and user experience.

Discover how overmoulding in injection moulding, product design, and industrial design can enhance your product development and user experience.

Selecting the right plastics manufacturing method for your project requires navigating a varied landscape of options, each with its unique benefits and challenges. This can be a daunting task. This guide aims to simplify that choice by providing a detailed comparison of popular plastics manufacturing techniques. From injection moulding and blow moulding to advanced 3D […]

In a world where everyone’s attention is pulled in all directions, the details of product branding matter. Companies strive to make a lasting impression on the customer, driving brand awareness, familiarity, and a relationship between the company and the customer. One effective way to achieve this is through the incorporation of logos on their injection […]

In the world of manufacturing, the precision and quality of your products are paramount. At the heart of manufacturing, especially in industries relying on plastic components, lies the process of injection moulding. This method generally uses multiple moulds that come together and close to form a “cavity” that is the shape of the manufactured product. […]

As your concept progresses through the design and development phases, it’s important to think about how you want your product to be manufactured. If you’re looking to produce it in a large volume, then injection moulding can be the way to go. What is injection moulding? Injection moulding is a manufacturing process for producing parts […]

Once you’ve taken your concept from design to manufacturing-ready, then the next step is deciding on the best product packaging. Packaging is essential to ensure your product is protected during shipping and to make it look appealing to customers. The days of ‘don’t judge a book by its cover’ have passed. Appealing packaging is important […]

Product design is a journey that transforms ideas into tangible, functional, and aesthetically pleasing products that improve our lives. Whether it’s a sleek smartphone, a comfortable piece of furniture, or an innovative kitchen appliance, the process of bringing a concept to reality involves a series of well-defined steps. In this blog, we’ll take you through […]

In today’s rapidly evolving world of product manufacturing and design, innovation is the key to staying competitive and meeting the ever-changing demands of consumers. Modern techniques have revolutionised the industry, allowing for more efficient and sustainable production while pushing the boundaries of product design and industrial engineering. In this blog, we’ll explore five innovative product […]

Thinking of getting your product manufactured? If so, choosing the right material for your product is an important decision that can impact its success. The material that you choose impacts not only your product’s performance and durability, but also its aesthetics and cost. There are many factors that go into choosing the right material, and […]

Manufacturing is the process of converting raw materials into finished products. The process involves various steps that are undertaken in a systematic manner to ensure the production of high-quality goods. In this guide, we’ll take you through the essential steps involved in product manufacturing and provide you with valuable insights that can help you develop […]

Are you looking for an efficient and cost-effective way to manufacture your product? Look no further than injection moulding. Injection moulding is a manufacturing process that involves injecting molten plastic into a mould to create a solid product. This process offers several advantages over other manufacturing methods. In this article, we will explore four advantages of […]

Are you in the final stages of designing your product? If so, it’s time to think about manufacturing. If you’re looking to produce your product in a large volume, then injection moulding can be the way to go. In this blog, we’re giving you a comprehensive guide to injection moulding, so that you can know […]

Have you got an idea for a product? Are you wondering how to take that idea from a concept to reality? If so, you’ve come to the right place. In this blog, we’re stepping through the 6 steps of the product design process so that you can know what to expect. Brainstorm The first step […]

Once you’ve designed, prototyped and tested your product, the next step is to manufacture it. Manufacturing will take your idea from conception to reality. Product manufacturing may sound like a complex process. However, it can be broken down into four simple steps. In this blog, we’re stepping through the 4 steps of product manufacturing so […]

Using recycled plastics can have big benefits, not just in reducing the overall cost of the manufacturing process but also the environmental impact it has by reducing the amount of plastic going into landfill. More often we are finding customers are wanting to use recycled plastics in the manufacture of their products. In this blog […]

Are you in the process of creating a new product? If so, you may be wondering about the differences between product research and development.  What is Product Research? Research is a learning process. This is when we try to define the way things work and to more clearly understand them.  It’s about asking wide open […]

Plastic is a durable material that is designed to stand the test of time. It can be recycled and used again and again.  Most plastics are used just once, and then end up in landfill or polluting the environment. Globally, eight million tonnes of plastic waste is dumped into our oceans. Moving away from single-use […]

So, your design is done! Looking back over your masterpiece, do you notice any overhangs or what is more affectionately known in the injection moulding industry as “undercuts”?  You may not realise that these little cliffhangers can have your design on edge, but why is this? In today’s blog, we discuss why you should try […]

Looking for a silver lining from the COVID-19 pandemic? After years of disruptions and strict border policies, there has never been a better time to manufacture in Australia. There is growing support for local manufacturing, with less reliance on overseas suppliers and manufacturers The pandemic highlighted the vulnerability of our supply chain, the risk to […]

When was the last time you went out for sushi and had soy sauce in any other type of container? No one says that it must be packaged like this, and frankly, other fish paraphernalia just isn’t perceived the same, but you wouldn’t trust soy sauce that came from anything else.  The soy sauce container […]

Here at Dienamics, we have been pushing carbon neutral practices through the use of multiple new technologies. It is our goal to become carbon neutral and we have invested time and money into new technologies and strategies in an effort to become more eco friendly.  This year, we have invested in more solar panels for […]

Plastic products are all around us in our daily lives. Have you ever wondered what it would be like to live without plastic products?  The future of plastic manufacturing seems hazy, given all of the environmental concerns about plastic. Many people are trying to move away from traditional plastics in search of more sustainable alternatives.  […]

If you’re in the process of designing and developing your product, then rapid prototyping might be an option for you. Rapid prototyping is a quick way to create a physical part from a computer design. It gives you an idea of what your final product will be like and allows you to quickly evaluate your […]

Prototyping is an important stage in the product design and development process. If you want your product to be a success, then you need to prototype it. So, what is prototyping? A prototype is a simple model of a proposed idea or solution. It is used to test or validate ideas so that refinements can […]

Have you got an idea for a new product that you want to make a reality? Designing a new product is great fun, but can have some challenges. Here’s 5 things you need to know before setting off on your journey to design a new product: Who will use your product? The first step in […]

Most people would hear the term tool making and assume it is about making hammers, screwdrivers and spanners. In actual fact a toolmaker is a trade professional who builds Moulds, Dies and jigs. They are an essential part of product development and the manufacturing of plastic products. If you’re looking to get your product developed, […]

Last week’s blog was all about Cold Runner Systems, this week, it’s time you learnt all about the alternate option – Hot Manifold Systems!  To reiterate last week’s blog, the runner system is what controls the distribution of the plastic from the moulding machine’s nozzle to the tool cavities. If you haven’t already read it […]

Injection moulding is one of the most popular methods for manufacturing and mass producing plastic products. It can be used for a wide range of plastic products, from a button for your shirt, to parts for a car.  If you’re thinking of using injection moulding to produce your product, the first step is to choose […]

Have you ever gotten an injection? A flu shot? A vaccine? Anaesthetic? If the answer is yes then it’s almost guaranteed that a plastic injection moulded syringe was used.    With plastic manufacturing becoming more reliable after WW2, the use of plastics in consumables began to become common practice, and with this even more progress […]

Once your product has been designed, prototyped and you’ve ironed out any issues, it’s time to think about manufacturing. There are a few different techniques that could be used to manufacture your product. To decide which process is best for your product, think about: Market demand for your product Availability of resources The amount of […]

Once you’ve developed your product, it’s important to keep innovating and improving it for maximum success. When your product is launched and customers start to purchase and use it, you’re going to receive feedback on how well it performs. If you take this feedback on board, you can continually improve your product for future success.  […]

As 2021 draws to a close, it’s time to reflect on the changes that this year has delivered to the design industry.

When products are manufactured, the process follows a set of instructions laid out by the designer in their bill of materials (BOM).

Two highly effective and time-tested manufacturing techniques are Injection Moulding and Rotomoulding. Both techniques have their own distinct advantages and disadvantages and may or may not be suitable for your moulding requirements. 

As your concept progresses through the design and development phases, it’s important to think about how you want your product to be manufactured.

When you’re in the process of taking your idea from a concept to a product, creating a bill of materials is an important step.

When it comes to injection moulding, there are many factors you need to consider to make sure you are putting the tool in a suitable machine and tonnage is an important one!

When you’re looking to take your concept to the next stage of mass production, it’s important to approach manufacturers with the right set of details.

So, you’ve got a killer idea for a product that’s going to revolutionise your industry. But, how do you take your product from design stages to reality?

As materials, technology, and circumstances change, so must the way we design and innovate products for manufacture… or they won’t be successful. Here we explore the reasons why design innovation is important in product manufacture.

In this article, we will dive into the top reasons why you should utilise rapid prototyping for your ideas, parts, and products.

When it comes to product design, I’d go as far to say that it’s impossible to reinvent the wheel. This is because the ability to create new things is founded on copying, transforming, and combining things with other things that already exist. Yes, the end result may be unidentifiable from that which inspired it, though it’s still integral in the process.

Rapid Prototyping and 3D printing are often mistaken for being the same thing, however there are some important differences.

We will take a look at the 4 main steps you need to take to manufacture products… Tool making, mass production, assemble and packaging

DFM’ isn’t a service, it is an inherent requirement of a products’ design. If your product hasn’t been designed to be manufactured, it isn’t a product design at all, simply an expensive and unusable CAD file. 

As more and more companies move toward sustainability in their products, there have been some pretty impressive products made from recycled plastics that have hit the market.

China was long thought to be the top player in the cost-effective mass production of goods. However, the coronavirus crisis has highlighted Australia’s need to move away from our large reliance on overseas production.

Sustainable manufacturing is now more necessary than ever and product design plays an important role in creating the opportunity for sustainability in product manufacturing.

This year has been like no other, and as we come to the end of it, we’re taking a look back at some of the top inventions that we’ve had the pleasure of working on!

3D printing has been around since the 1980s, and over time has transformed many industries and manufacturing operations. Today, it’s one of the world’s most substantial and transformative technologies. Discover where 3D printing technology is headed in 2020 in Australia. But first, here’s a little information about the process… 3D printing is a manufacturing technique […]

Part 6 – Vacuum Casting In Part 5, ‘SLS 3D Printing,’ we looked at each consideration for the process, step by step. In this edition of our knowledge series, we’ll be discussing the considerations needed for vacuum casting. Vacuum casting (vac-casting), is a plastic moulding process used to manufacture high quality product prototypes. Vac-casting works […]

Part 5 – SLS 3D Printing In Part 4, ‘User Testing and Research,’ we talked about the importance of the user testing and research phase of making your prototype. In this edition, SLS Printing, we’ll look at the considerations for the process, step by step. Originally developed back in the 1980’s, Selective Laser Sintering or […]

Part 3 – Types of Prototypes In Part 2. ‘Before You Prototype‘, we looked at the importance of developing a clear understanding of why you are prototyping and what you’re wanting to achieve from it. In this issue, we’ll list some of the different types of prototypes and their purpose; we’ll go into depth on […]

$12 Outdoor Plastic Chair off Gumtree Not as Mechanically Sound as First Thought Local father figure, and little league coach, Bryan Walters (42) returned home yesterday after a day in the sun to sit down and enjoy a cold-one on his newly renovated outdoor patio. Much to Mr. Walters’ dismay, the bargain lawn chair he […]

We often get asked, are all steels the same? In fact, it’s one of our frequently asked questions. The short answer (and the one featured in our FAQs) is – No, there are different grades and hardness of steels. Hard steels tend to last longer but are more difficult to machine and heat treat. But […]

Creating a perfect part begins with creating the perfect mould. Easier than it sounds.

Look around you, how many electronic devices can you see? …3….4….8? More than 23.5% of household fires are started by electrical products or electrical appliances; such as televisions, radios and power adapters. Often, these products are made from plastic or contain plastic components. Classed as ‘ordinary combustibles,’ most plastics are excellent fuels and are in […]

The plastic injection moulding process is highly technical, and by no means an easy job. There’s a lot of room for expensive error, which can range from minor defects to major issues that could affect your product’s performance, desired design result, and safety.

Although it’s probably not something you think about often, coloured plastics are an essential cog in the industrial design machine. Try to imagine the design process without it – it’s impossible! The truth is that you can’t have one without the other. Coloured plastics are an essential element in the tool making and manufacturing process […]

  Plastic injection moulding is by far the most popular method for producing mass manufactured plastic products – though if you’re new to the design and manufacturing game, here’s a quick recap. An injection moulding machine has a few main elements; a material feeder, called a ‘hopper,’ where plastic granules are poured; a heated barrel […]

For some, the cosmetic appearance of a part is the last thing on your mind. It might be that the part is being used internally, hidden from view, or the appearance is not a key point of sale for your part or product. But for many, the cosmetic appearance is of great importance, and something […]

We recently discussed the rise of hemp bio-plastic being used as a plastic alternative and how this could impact injection moulding. Although the usability across the industry is still limited, it is indicative of the growing movement towards alternative plastics. These alternative, or bio-plastics, are leading the way for the manufacture of products and packaging […]

The Dienamics team has recently welcomed two new machines to the workshop! Both new machines offer excellent energy-saving capabilities and are a huge step in the right direction for Dienamics becoming a more environmentally friendly manufacturer. The machines are 90 tonne and 160 tonne. Tonnage, also known as clamping force, is the measurement which represents […]

The topic of hemp-based products has been very popular recently in the news and media. Its seeds and flowers are mostly used in nutraceuticals, however the stalks and fibers can be used in construction materials, paper, biofuel, and clothing. People are favoring it as a good production material for its fast-growing ability and environmental sustainability. […]

It is essential to consider the location of a facility when looking for a manufacturer. While many businesses are choosing to manufacture overseas due to cheaper production and labour costs, more often than not it pays to keep your company based right here in Australia. Overall, there are many benefits to choosing a manufacturer based […]

If you’re a manufacturer of products that utilise plastic parts or you’re in the process of becoming a manufacturer, it’s likely you’ve considered getting a quote for injection moulding. As injection moulders, we are known for our ability to help product engineers get their item to market efficiently and cost-effectively. Obtaining an injection moulding quote […]

There are many steps between a great product idea and launching to market. It’s important to transition through each, even if you feel you don’t need it because doing so will better prepare you to launch the best possible product…and you might discover some issues you hadn’t even considered. But it’s also important to know […]

In our current manufacturing environment, plastics are being used to create everything from vehicle parts to buttons on clothing and even human body parts. For every application, a special and specific manufacturing process is required so that each part can be moulded based on its specifications. If you’re interested in manufacturing a plastic part, one […]

More than 300 million tons of plastics are now being produced every year. Half of that is estimated to be single-use plastic, and approximately 8 million tons of plastic finds its way into the oceans every year. Plastic has become such an integral part of our lives, but it has also clearly become an environmental […]

Not all plastics are created equal. Indeed, the first step in the plastics recycling process is to identify which type of plastic you are dealing with. For recycling purposes, plastic is divided into seven distinct families. Here, with examples of their most common uses: 1. PET (Soft drink bottles) 2. HDPE (Milk and cream bottles) […]

Trying to figure out what plastics can and can’t be recycled? Many people mistake the numbered triangle on plastic products as the recycling sign, but these symbols are actually the Plastic Identification Code and they classify the type of plastic material. There is conflicting information about which plastics can be recycled in kerbside collection, and […]

Bob “The Bee Man” Luttrell came to Dienamics with an idea for a honey frame designed to harvest clean, clear honey without sacrificing quality or bees. The structure differed from the regular honeycomb shape of beehives, instead using a square framework. This design allows for honey to be harvested effectively, but most importantly, without harming […]

LandCruiser’s are known as the work horses of Toyota 4WD’s – tough, reliable, and built for off-road driving and work. But the one thing LandCruisers (particularly the 70 Series) don’t have is a flash interior. But that doesn’t mean they can’t. Cruiser Consoles came up with a brilliant idea to fill a hole in the […]

What is Reaction Moulding? Reaction Moulding is a type of moulding that induces a chemical reaction between 2 types of resin. It commonly produces products with a foam core, with the foam varying from soft and bouncy to rigid and strong. Reaction Injection Moulding (RIM) typically make larger, light but strong parts. The basic process […]

How does an Autoloading Hopper work? An autoloading Hopper is just like a regular hopper, except that it can load material from storage bags around the machine. It does that by using a vacuum placed on top of the hopper. This vacuum is caused by a fan, connected to an electric motor. As the fan […]

How does an Ultrasonic welder work? An Ultrasonic welder is a machine that uses kinetic energy from vibrations to heat and melt plastic together. The basic process comes down to a vibration frequency, measured in hertz, directing energy onto a section of the 2 parts you want to weld together. This often gives a better […]

How does a Sprue Picker work? A sprue picker is a piece of specialized machinery that picks the sprue out of an injection mould, usually as the parts are being ejected. The sprue picker can then drop the sprue to either the operator side or the far side of the injection moulding machine. Now let […]

How does a Regrinder work? A regrinder or plastic granulator is an electrically powered series of grinding blades, which takes plastic and chops them up into little pieces, commonly referred to as regrind. This regrind is a major step in any plastics recycling scheme. It takes what was reject or waste plastic and breaks it […]

Choosing the right plastic for any given project can be tough. Some are more rigid than others, some are better moisture and oxygen barriers, and there can be vastly different temperature tolerances. There’s always going to be a trade-off when it comes to strength, heat resistance, flexibility, finish, and most importantly, cost. The best way […]

How does a Metal Press work? A press is simply a flat bed, and a pressing ram or rod, that is actuated either hydraulically/pneumatically or mechanically. To make a metal pressed part, you insert 2 halves of a metal press tool into the press. You then bolt the bottom of the tool to the work […]

The Idea The path ore bearing rocks take on their way from the mine site to sale is a rough one. They are extracted with explosives, shifted by draglines, put through rock crushers and piled into mountains that can sit out in the elements for years on end. So how do you embed delicate electronics […]

How does a laser cutter work? A laser cutter uses an extremely powerful beam of focused light and projects this onto a sheet of material. This light beam has so much energy that it melts or vaporizes the sheet material, leaving a cut in its wake. Laser cutting does have a high tolerance, especially when […]

Peter Reid, a Senior Research Engineer from the CSIRO, had a problem. As part of a research project at Pullenvale, Peter was developing a machine that helped to map and survey mine sites using advanced technologies. Requirements He was using LiDAR and other light-based sensors to survey the mine. What he needed was an optically […]

Warpage: it’s the bane of the designer when it comes to injection moulding. Warpage occurs when cooling of the part is inconsistent. A section of the part will set whilst another remains molten. The set area will restrict the proper setting of the still molten area, resulting in warped parts that must be rejected or […]

Blow moulding products all have one thing in common: they are hollow and in one piece. It’s often used for glass and plastic products like bottles, jars, and containers. It’s a cost effective and quick method of moulding, but that doesn’t mean it’s not without its disadvantages. The process is limited to only making hollow […]

How does an Injection Moulding Press work? An Injection Moulding Press or Injection Moulding machine is a rather complicated, fully automated piece of machinery. An injection moulding machine makes moulded plastic parts quickly and with a high degree of repeatability. The plastic parts can be made from a range of different plastics for different purposes. […]

Breathing – Most people don’t give it a second thought. But for some of us, something as simple as taking a breathe is not so straightforward. The team at AirPhysio knew they could help. The idea They developed the concept for the AirPhysio Oscillating Positive Expiratory Pressure (OPEP) device. Like all good ideas, the concept […]

The world’s first fully synthetic plastic was bakelite, invented in 1909 in New York by Leo Baekeland, who also coined the term ‘plastics’. Before that, semi-synthetic plastic products like celluloid and PVC rocked the late 19th century. The invention of parkesine in 1862 led the course and started a wave of plastic production that shaped […]

What is Pultrusion? Pultrusion is a process that flips the logic of extrusion. Instead of feeding material into a hopper, and forcing it through a die, the raw material is rolls of pre-impregnated (pre-preg) fibre filled polymers threads. These threads are pulled through the entire assembly line during setup. The threads from their spools, run […]

Resin Transfer Moulding (RTM) is a process that injects a two-part resin mixture that fills a mould under high pressure. In the mould there is also a fibre based preform. As the mould heats, the resin is cured into a solid shape and the part is ejected, with the fibre center preform being wrapped in […]

What is Compression Moulding? Well I can tell you it’s one of the first moulding techniques ever used widely in the beginning of the Plastics Industry. The basic principle of Compression Moulding is that you have a pliable or dough-like material, sometimes in a preform or just in granules in two mould halves. You then […]

Injection moulding is a versatile process and can be applied to almost any product. Although injection moulding is the industry standard for fabricating parts for products, it is not without its holdups. There are a few basic limitations to be taken into account. Here’s eight rules to follow when designing your product to ensure quality […]

Laser Cutting – you’ve heard of it or know someone who has, but what is the actual process of laser cutting? Well it uses a super-hot beam of light to melt, burn or vaporises stock material. In certain machines, laser cutting can produce anything from structural welds, clean cuts and even up to very fine […]

Polyamides (also known as PA, though commonly referred to as Nylon) are a family of engineering grade plastics, which are known for their immense tensile strength and high durability. They generally are semi-crystalline and have good thermal and chemical resistance. There are various grades of nylons, some common grades are Nylon 6 (PA6), Nylon 6,6, […]

The basic concept behind rapid Tool Design for injection moulding has remained unchanged for the past 20 years. However, it is important to understand this basic concept to ensure success with injection moulding. This article will outline the four steps to success in rapid injection moulding product design.

An injection moulding machine is a complex piece of machinery that creates one solid part by injecting molten materials through a reciprocating screw system into a mould. This machine is made of many components; it is primarily consisted of a hopper, a barrel containing a reciprocating screw, temperature control devices, a clamping unit and the […]

An injection mould is the key to creating a successful one-piece finished plastic or metal component. Melted material is forced from the injection moulding machine into the mould (which is usually cool) where it sets. The result is a solid piece of the material which may be a component to, or the whole of, a […]

Injection moulding is an efficient and effective way of producing quality goods. The process is simple in concept, but intricate details can have big impacts on costs, particularly on large production runs.

    Polypropylene (PP) is commonly sighted as the second most commonly used plastic on earth, by weight used yearly by industry. Polypropylene was first polymerized in 1951 by a pair of Phillips petroleum scientists named Paul Hogan and Robert Banks. The ability of polypropylene to crystallize created a lot of excitement, and Italian chemist, […]

Previously we discussed Thermoforming, today I wanted to talk about a subsection of that category of plastics manufacturing known as Vacuum Moulding or Vacuum Forming. Vacuum Moulding is the process by which a thermoplastic sheet material is heated until it’s malleable and then sucked onto a forming core or tool using the pressure of a […]

Thermoforming is one of the most accessible and easy to understand manufacturing processes. As with all mass-produced products, you’ve probably used a thermoformed product without even realising it. For instance, high end boxed chocolates are often arrayed out in their box in a thermoformed tray. Yoghurt tubs, takeaway food containers, those plastic tubs your cherry […]

Undercuts. No Plastic Injection Moulder wants them and every DIY part design has them. Undercuts, are part and parcel of what we do here at Dienamics. Most of our clients are looking to create or improve their own products, but are restrained to a strict budget. So, one of the first things we look for […]

Polyurethanes (also known as PUR or UR) are a massive family of highly versatile engineering materials designed to provide properties not available in conventional rubbers, metals and plastics. Typically they have higher oil and solvent resistance, along with greater abrasion and tear resistance. Impact strength, low compression set and superior load bearing capacity are also […]

Gas Assisted Injection Moulding is a highly technical form of injection Moulding, that uses both plastic and gas (usually nitrogen) to fill an injection mould under pressure. The main benefit of this manufacturing process is that it’s ability to form hollow parts in the cycle time of injection moulding machines. The basic process of Gas […]

A sad fact of injection moulding and plastics manufacturing in general, is that plastic shrinks. And sometimes it shrinks a lot. So as plastic Injection moulders we’ve learnt to deal with shrinkage and today we are going to share a few of our tips and tricks to avoid excessive shrinkage and explain a bit about […]

ABS is purpose built to be easy, cheap, stiff and tough, all while being capable of displaying great surface finishes and colours. Originally developed in the late 1940’s, ABS combines the acrylonitrile, butadiene and styrene monomers with the intent of displaying the best of each of these elements. Acrylonitrile is highly process able and glossy. […]

Polyoxymethylene (POM), usually referred to as Acetal, is a widely used engineering plastic. Its primary claim to fame is its use in mechanical parts. If it has to bear a load, like a gear, a handle, a zipper or the foot on a piece of furniture, then Acetal is it the material of choice. As […]

Plastic Co-extrusion is very similar to Plastic Extrusion, however, with co-extrusion you are inserting multiple polymers into the extrusion dies to produce a single profile with a range of physical characteristics. In this article, we’ll cover the differences from regular plastic extrusion and the benefits and disadvantages to Plastic Co-extrusion. So the fundamental difference to […]

Stereolithography (SLA) is a type of rapid prototyping, AKA 3D printing. In this article, we will unpack the basic process, advantages and disadvantages of this manufacturing technique and decipher some of the jargon thrown about in the rapid prototyping industry. Basic Process The basic process of Stereolithography involves taking  CAD model of an object, and […]

In this article, we’re talking about gates. And no, not the kind that you shut behind you when you’re leaving the farm. In plastic injection moulding a Gate is where the molten plastic enters the cavity of the tool. That’s to say it’s different from the sprue or runner. Sprues and runners are simply there […]

Polyethylene terephthalate (PETE or PET) is one of the most commonly used thermoplastic polymers in the world and is better known in the textile industry by the trade name “polyester.” It is a naturally transparent and semi-crystalline plastic widely used as a fiber for clothing, as an effective moisture barrier with wide applicability in bottling […]

Polystyrene (PS) plastic is a naturally transparent thermoplastic that is available as both a typical solid plastic as well in the form of a rigid foam material. PS plastic is commonly used in a variety of consumer product applications and is also particularly useful for commercial packaging. Dow Chemical Company invented a proprietary process to […]

Extrusion is a simple process and is used the world over, from making spaghetti to window frames and door seals. Plastic Extrusion is when a material is being forced through a die (think a plate with a profile cut into it) and the plastic takes the form of that profile. In plastics, extrusion creates long strips […]

Threads are critical in Injection Moulding. Not only do they require more complexity in the tool design, the resulting plastic part must work perfectly, with next to no warpage and align perfectly when assembled. It’s important that you get it right the first time, so in this article we’ll explore what you need to know […]

We’ve previously mentioned the importance of wall sections in our article about Ribs in Injection Moulding so in this article we’re going to go greater depths with that subject. We’ll talk about the basic process of injection moulding and how it relates to wall thickness, then outline some of the problems that may occur due to […]

Polycarbonate is a naturally transparent amorphous thermoplastic. Although made commercially available in a variety of colors, the raw material allows for the internal transmission of light nearly in the same capacity as glass. Polycarbonate polymers are used to produce a variety of products and are particularly useful when impact resistance and/or transparency are a product […]

Blown Film is a manufacturing process that produce films of plastic sheeting and tubes. These sheets or tubes can either be fully cylindrical, or have other object inserted into them so they form useful objects like shopping bags, rubbish bags or cling wrap.  In this article, we will explore what the process of blown film […]

Living Hinges, it sounds weird, right? Especially when you are talking about plastic product. There’s nothing “living” about plastic. In this article, we are going to unpack the Living Hinges (also known as integral hinges) in Injection Moulding and why they should be in your product. A living hinge is basically a thin bridge of […]

Rotational Moulding (Also known as Roto-Moulding or Rotational Casting) is great at making hollow objects. In fact, you probably enjoyed a roto-moulded product over Easter. Hollow chocolate Easter Eggs are roto-moulded, and so are kayaks, water tanks and hollow kids’ toys. In this article, we’ll show you the basic process of roto moulding and its […]

Polyvinyl Chloride (PVC) is an unsung hero of the plastics industry. Whenever there is a dirty outdoor job, PVC is often the go-to material. PVC has been around longer than most plastics having been first synthesized in 1872 and commercially produced by B.F. Goodrich Company in the 1920s. By comparison, many other common plastics were […]

  Let’s talk about bosses. And no, not the ones whipping you to do more work, but the rather helpful ones in plastic injection moulding. Bosses are design elements that strengthen parts. We’re going to unpack why you should have bosses, how to design them appropriately and some common part failures which can be avoided […]

Flashing is one of the most common flaws found in injection moulded parts. Flash is fine, feathery sections that stick out from a finished part, usually at right angles to the wall section they connect to. What causes it? Sneaky plastic, that’s what. Technically, flash is plastic that has escaped from the mould cavity along […]

In our explorations of manufacturing techniques we have covered a number of ways to mass produce plastic parts. Today, we will look at one the one I like to think of as the most underappreciated, Blow Moulding. Blow moulding isn’t as well known as injection moulding, yet it is responsible for a creating fantastic number of […]

Crack open almost any plastic shape and you will the internal volume is mostly air, and anything that actually does any work inside the part is reinforced by a strange pattern of thin little walls. Those little joining walls are called ribs, and they are one of the most important and powerful parts of any […]

When you’re developing your product, the designer might come to you and say “I want to reduce the wall thickness in your part” even though you’ve said time and time again that you want a strong durable product. So why do designers push for thin walls? Let’s find out… There are three main reasons injection […]

Flow Lines are a family of cosmetic flaws which can occur in injection moulded plastic parts. We would like to share our experience with you to aid you in spotting these flaws, and understanding how to avoid them The Flow Line family of visible marks can be defined as marks which make the route the […]

In June 2007, Steve Jobs introduced the iPhone to a twitchy crowd of Apple acolytes. Much wonderment and applause ensued within the walls…but outside, scepticism was rampant. Many balked. Many were wrong. By the same time the next year, it felt like the whole world either owned an iPhone 1st Gen or intended to. A […]

Polyethylene is the plastic worlds jack of all trades, the ultimate do anything tool. Like all good tools, its power lies in its simplicity. Let’s look at how the most common human made plastic on earth conquered applications ranging from food covering to ballistic protection, and how it might just work in your project. All […]

Die Casting is the injection of molten metal into a Die (similar to a Mould) under pressure to create complex parts out of metal. Die Casting is conceptually very similar to injection moulding – just with molten metal instead of plastic. Die Casting is primarily a mass production method, where the costs of setting up […]

Injection moulding is an affordable, versatile, and efficient manufacturing process that has earned an admirable place within the business of any production company. It’s used to make everything from Gameboys to gears, and with the process standing as one of the best options for businesses developing products. There’s a myriad of benefits to swapping over […]

“I’m sorry, but I can’t read that format” Anyone trying to get something built has hit the problem. Your concept has left the drawing board and entered the computer realm. Modelling, drafting, rendering and many other “ing’s” have been paid for, and you’ve seen pictures that are beginning to look like just the thing you […]

Sink marks are a common manufacturing flaw found in injection moulded parts. Here is how to identify them, and avoid them.

Injection moulding is one of the most widely used polymer-moulding techniques in the world. It is used to produce everything from automotive parts and gear transmissions to furniture and household items. Cost factors One of the reasons why injection moulding has been so widely used is due to its cost benefits. The injection-moulding process is […]

Plastic injection moulding is used to produce everything from vehicle parts and bodies to buttons on clothing. The impact of plastic injection moulding is visible in the daily lives of millions of people, with the average household containing a number of items created through this vital manufacturing process. However, few people understand just how plastic […]

The modern human owes many of his or her daily conveniences to the technique known as plastic injection moulding. This manufacturing technique has been in use since the 19th century. Key steps Key steps in the plastic injection moulding process include clamping, injection and cooling: Clamping keeps the mould in place under heating and other […]

Plastics are used for their versatility and flexibility in application. They can be used in everything from body parts to automotive components. The process of creating these parts involves a moulding process, and these are some of the most common types of moulding techniques in use. Blowmoulding This type of moulding is suitable for hollow […]

Injection moulding is a plastics moulding methodology that is known for its reliability. It is widely used, with applications from large pieces to small computer components. These are some of the key industries in which injection moulding is widely used. Computing and electrical industries Computing and electrical parts use plastic components to hold moving parts […]

Drinktec 2013 was held during the month of September. This year, the Munich exhibition showcased injection moulding machines by Arburg and Engel. Engel Engel showed its e-cap 3440/380 injection-moulding machine that had a 72-cavity mould. The mould was created by z-moulds, a specialist Austrian toolmaker. The cell has the capacity to produce 1.8g still water […]

As standardized mass production techniques develop to cater for low-grade affordable consumer goods, experts are looking to high-end manufacturers for small batch high-value products. Electronics manufacturers are the first to recognize that quality production techniques are important. Leading manufacturers of audio equipment, testing instruments and automobile parts are pushing the boundaries of quality, diversity and […]

Manufacturing processes hinge on the practice of making large quantities of uniform items. Creating uniform items allows for a standardised quality of product, which is one of the fundamental premises of market economics. Manufacturers will make as many copies of an item as they can without compromising their product’s quality. Technical advances have allowed for […]

A new paper by The Linde Group has revealed that carbon dioxide (CO2) can be used to cut cooling cycles and overall production cycles in injection moulding. The white paper is concerned with the manufacturing technique of gas assist injection moulding, which traditionally uses nitrogen as the gas of choice. However, the paper revealed that […]

A new book, Brick by Brick: How LEGO Rewrote the Rules of Innovation and Conquered the Global Toy Industry, has traced how Lego made its recovery from the brink of bankruptcy by returning to its roots. In this book, Wharton professor David Robertson revealed how the Danish toy maker made resurgence from near bankruptcy by […]

Over the summer, 10 students from various departments at UC Davis have been getting together at the university’s Genome Centre to address the issue of plastic in landfills. The students are members of the UC Davis International Genetically Engineered Machine (iGEM), team and have been working on a special project for the world’s premiere collegiate […]

These days, consumers increasingly want to buy more sustainable products, and companies like AT&T are rising to the challenge. Over the last year, AT&T has been making headway in the field of sustainability, from accessory packaging made from 30 per cent plant-based materials, to creating a consumer-focused sustainability website, called EcoSpace, where customers can recycle […]

In a push to manufacture the highest quality handcrafted boating paddles with the greatest amount of aesthetic appeal, Werner Paddles went on a quest to find the perfect material that would meet its standards. “For Werner, the cosmetics of the material were as important as the strength, rigidity, and other physical properties,” explained Tim Bailey, […]

Very recently, an old relic has resurfaced from the ‘90s electronics junk heap to become useful once again: the plastic injection moulds that were used to make the plastic components for the Atari Jaguar. These moulds, which cost Atari US$250,000 to design and build in the first place, were part of a “tooling package” that […]

Until recently, most third party inspectors have used a fixed-base Coordinate Measuring Machine (CMM) to inspect the accuracy of plastic injection-moulded refrigerator parts. 3D Engineering Solutions, an ISO 17025 certified third-party inspector, has since announced the successful use of new scanning technology that captures millions of data points during inspection rather than just hundreds. Rob […]

To be successful in today’s manufacturing industry, you need more cost-effective and efficient techniques for manufacturing products. Historically, manufacturers mass produced products based on predicted future demands, but this system often resulted in wasted effort and resources when customers failed to live up to expectations. Modern companies simply can’t afford to operate that way, and […]

Every product you see at any store was probably delivered on a pallet. There are many different types of pallets, with wood and plastic being the most common. Thanks to plastic injection moulding, plastic pallets are designed for both space-efficiency and durability. Whether you’re moving or plan on opening a store, you can use plastic […]

Plastic injection moulding is a booming industry. Almost every product in the 21st century requires plastic in one form or another. The invention of plastic was one of the greatest achievements in industrial production due to the fact that it’s synthetic and not limited in nature. Here are the eight most important types of plastic […]

Few things are as ubiquitous as the plastic bag. Full of utility, a plastic bag is not only an efficient way of carrying things around, but it also serves as an efficient and reusable storage device. However, few people really know the history of the plastic bag, even though it is so prevalent in our […]

Most plastic products are created using a common manufacturing technique called ‘plastic injection moulding‘. During this process the raw material, some form of plastic, is completely melted and then inserted into a special mould. Then the material is cooled and expelled immediately. Most of the plastic items and products we use in our everyday lives […]

Most people are not aware of what plastic injection machinery is. In terms of product design, all of us are surrounded by plastic objects made with plastic injection machines – such as water bottles, telephone handsets, CD covers, dust bins, electric outlets and a lot more. Did you ever realize that these commonly used items […]

A lot of people go through life with no real interest in the ‘behind the scenes’ stuff. They don’t want to know where their dinner came from, they just want to know it’s in front of them. They have a similar opinion on everything from how their car works to the physics that drive our […]

Today, plastic injection moulding is responsible for the creation of products as varied as buttons and toys to state of the art computer touch screens and parts for aerospace products. A versatile and incredibly useful process, plastic injection moulding has paved the way for modern invention and design, and is something the world today could […]

The evolution of manufacturing techniques and product design has resulted in a world full of incredibly impressive constructions feats. Let’s take a look at some of the world record holders. World’s Longest Bridge At over 164km long, including 9km of over-water section, China’s Danyang-Kunshan Grand Bridge is part of the Beijing-Shanghai High Speed Railway.

Injection moulding is a manufacturing method where plastics are shaped (or ‘moulded’) to form all kinds of objects that we use in our everyday lives. If you’ve ever sat on some plastic lawn furniture, unscrewed a plastic bottle cap or combed your hair with a plastic comb, then you’ve probably used an item that was […]

Blow moulding is also known as blow forming, and has widely been used since the 1800s. It is best suited for the product design and manufacturing of hollow plastic parts, such as with the production of plastic bottles, with uniform thicknesses when the outside shape is the major consideration. The basic process. A heated plastic, […]

Die casting is a very versatile process for producing highly engineered metal parts. Molten metals are forced into reusable steel moulds. These moulds are often called dies, and are designed to produce the complicated shapes that we see in many consumer products ranging from kids toys to automotive parts. The dies, are essentially the reverse […]

For those of you who want to know a little more about plastic injection moulding, this article will attempt to explain, in layman’s terms, exactly what this means. Basically, injection moulding is a process that was first designed in the 1930s. Up until then die casting, or the process by which metals are cast from […]

Steel is a catch-all phrase use to describe a group of iron alloys. These alloys all have one thing in common: malleability. Steels can all be melted down and used in the injection moulding process to create everyday items. Steels can be cast directly into moulds, or can be made into other forms which allow […]

Plastics are the common name for man made polymers. Chemically, these materials are made up of a single unit, the monomer, which will link up with millions of itself to form long chains. The length of these chains, if they have many branches, and how tightly they wrap together determine the physical properties of the […]

Bosses are small cylindrical elements in a design. They are used for accepting screws or other fastening components (threaded inserts usually). Essentially they are locating, mounting and assembly devices built in to the design of the part and if not for accepting screws, will attach to the mating part of another component of the design. […]

When you’re developing your product, the designer might come to you and say “I want to reduce the wall thickness in your part” even though you’ve said time and time again that you want a strong durable product. So why do designers push for thin walls? Let’s find out…

The concept of injection moulding is simple enough. First, the moulder fills the machine with plastic pellets. Then colorants are added to create the desired colour (we can do just about any colour by the way, even metallic hues). After that the plastic is heated up to its melting point, liquefying it. The molten plastic […]

To ensure a successful finished product, you need to be aware of the process that goes into making your component. This should be at the forefront of your mind when considering the design of your part. Injection moulding will provide you with the component you want, and if you are able to consider its process […]

When designing for manufacture with injection moulding, there are still more guidelines to be taken into consideration. The easier it is for the Toolmakers to create your mould, the faster your turnaround time will be, increasing the speed that your product will be out there for consumers. Here’s 10 more design guidelines to follow when […]

There are many factors to consider when designing for manufacture through injection moulding. You need to make sure your product can be accurately and consistently produced, yet it may need particular features or parts that will require extra efforts on the part of the Toolmakers. To ensure your design is smooth and the injection mould […]

Injection moulding can do almost anything. This technology, created in the 1940s and constantly refined, allows for incredible flexibility in product design and has effectively revolutionised mass production. Injection moulding is the process of forcing molten materials into a mould or die. The material is then cooled, the finished result taking on the physical characteristics […]