Injection Molder - Revision history

Plastichub: removed referral

2023-06-01T18:54:46Z

removed referral

← Older revision		Revision as of 18:54, 1 June 2023
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	*The Secrets of Building a Plastic Injection Molding Machine - Vince Gingery [http://www.amazon.com/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon US], [https://www.amazon.co.uk/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon UK], [http://www.btmon.com/Gingery_Books.rar.torrent.html BTMon]		*The Secrets of Building a Plastic Injection Molding Machine - Vince Gingery [http://www.amazon.com/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon US], [https://www.amazon.co.uk/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon UK], [http://www.btmon.com/Gingery_Books.rar.torrent.html BTMon]
	*[http://rick.sparber.org/Articles/gpi.pdf A Modified Vince Gingery Plastic Injection Molding Machine] - Rick Sparber, 2010		*[http://rick.sparber.org/Articles/gpi.pdf A Modified Vince Gingery Plastic Injection Molding Machine] - Rick Sparber, 2010
	*[https://kb.osr-plastic.org/academy/build/injection/] - OSR-Plastic Injection Machines

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Plastichub: osr-plastic reference

2023-01-17T06:42:40Z

osr-plastic reference

← Older revision		Revision as of 06:42, 17 January 2023
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	*The Secrets of Building a Plastic Injection Molding Machine - Vince Gingery [http://www.amazon.com/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon US], [https://www.amazon.co.uk/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon UK], [http://www.btmon.com/Gingery_Books.rar.torrent.html BTMon]		*The Secrets of Building a Plastic Injection Molding Machine - Vince Gingery [http://www.amazon.com/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon US], [https://www.amazon.co.uk/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon UK], [http://www.btmon.com/Gingery_Books.rar.torrent.html BTMon]
	*[http://rick.sparber.org/Articles/gpi.pdf A Modified Vince Gingery Plastic Injection Molding Machine] - Rick Sparber, 2010		*[http://rick.sparber.org/Articles/gpi.pdf A Modified Vince Gingery Plastic Injection Molding Machine] - Rick Sparber, 2010
			*[https://kb.osr-plastic.org/academy/build/injection/] - OSR-Plastic Injection Machines

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Eric: Added some more links under the "See Also" section

2020-02-26T04:14:56Z

Added some more links under the "See Also" section

← Older revision		Revision as of 04:14, 26 February 2020
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	==See Also==		==See Also==
			*[[Precious Plastic Manual Plastic Injection Molding Machine]]
	*[[Precious Plastic]]		*[[Precious Plastic]]
	*[[Bioplastic Extruder]], for producing continuous forms such as pipes, and for very high-pressure moulds.		*[[Bioplastic Extruder]], for producing continuous forms such as pipes, and for very high-pressure moulds.

Eric: Added some more links under the "See Also" section

2019-03-01T18:35:44Z

Added some more links under the "See Also" section

← Older revision		Revision as of 18:35, 1 March 2019
Line 67:		Line 67:

	==See Also==		==See Also==
			*[[Precious Plastic]]
	*[[Bioplastic Extruder]], for producing continuous forms such as pipes, and for very high-pressure moulds.		*[[Bioplastic Extruder]], for producing continuous forms such as pipes, and for very high-pressure moulds.

4ndy: Moved bibliographic links from See Also into References. Added a torrent link for Gingery's two-decades-old books. Fuck da police. Open Source Everything.

2014-12-03T21:21:35Z

Moved bibliographic links from See Also into References. Added a torrent link for Gingery's two-decades-old books. Fuck da police. Open Source Everything.

← Older revision		Revision as of 21:21, 3 December 2014
Line 68:		Line 68:
	==See Also==		==See Also==
	*[[Bioplastic Extruder]], for producing continuous forms such as pipes, and for very high-pressure moulds.		*[[Bioplastic Extruder]], for producing continuous forms such as pipes, and for very high-pressure moulds.
	*The Secrets of Building a Plastic Injection Molding Machine - Vince Gingery [http://www.amazon.com/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon US], [https://www.amazon.co.uk/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon UK]
			==References==
			*The Secrets of Building a Plastic Injection Molding Machine - Vince Gingery [http://www.amazon.com/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon US], [https://www.amazon.co.uk/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon UK], [http://www.btmon.com/Gingery_Books.rar.torrent.html BTMon]
	*[http://rick.sparber.org/Articles/gpi.pdf A Modified Vince Gingery Plastic Injection Molding Machine] - Rick Sparber, 2010		*[http://rick.sparber.org/Articles/gpi.pdf A Modified Vince Gingery Plastic Injection Molding Machine] - Rick Sparber, 2010

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4ndy: Improved piston sentence

2014-06-07T11:29:46Z

Improved piston sentence

← Older revision		Revision as of 11:29, 7 June 2014
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	==Detailed Description==		==Detailed Description==

	The Injection Moulder consists of a melt-chamber fed with chipped recycled plastic and/or pellets of virgin plastic feedstock, heated to a controlled temperature by a heater cartridge, heating resistor or some wound nichrome wire, and forced through a nozzle into a mould by a piston fitting the melt-chamber. For large moulds requiring high pressure, ~~the~~ piston ~~is often~~ driven by a motor using a leadscrew, but for small batches/parts a hand-operated lever is fine.		The Injection Moulder consists of a melt-chamber fed with chipped recycled plastic and/or pellets of virgin plastic feedstock, heated to a controlled temperature by a heater cartridge, heating resistor or some wound nichrome wire, and forced through a nozzle into a mould by a piston fitting the melt-chamber. For large moulds requiring high pressure, a piston can be driven by a motor using a leadscrew, but for small batches/parts a hand-operated lever is fine.

	A simple Arduino-programmed ATMega microcontroller with a potentiometer (analogue knob) or 7-segment display & tactile switches (digital) input driving a high-voltage relay with low-frequency PID, would easily suffice for temperature control.		A simple Arduino-programmed ATMega microcontroller with a potentiometer (analogue knob) or 7-segment display & tactile switches (digital) input driving a high-voltage relay with low-frequency PID, would easily suffice for temperature control.

4ndy: Clarified that milling was the main starting cost of conventional injection moulding.

2014-06-07T11:22:54Z

Clarified that milling was the main starting cost of conventional injection moulding.

← Older revision		Revision as of 11:22, 7 June 2014
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	The Injection Moulder enables fast production of highly repetitive/homogeneous parts such as plugs, switches, knobs, handles, etc.		The Injection Moulder enables fast production of highly repetitive/homogeneous parts such as plugs, switches, knobs, handles, etc.

	The embodied energy + wear & tear of ~~creating~~ a set of mould plates for production has historically limited this process to parts produced on a scale of many thousands or even millions, however, using a [[3D Printer]] and a [[Foundry]] it may be possible to cast cheap recycled-aluminium moulds in order to produce repetitive parts on the order of hundreds or more, which would otherwise cause excessive wear on a 3D Printer.		The embodied energy + wear & tear of milling a set of metal mould plates for production has historically limited this process to parts produced on a scale of many thousands or even millions, however, using a [[3D Printer]] and a [[Foundry]] it may be possible to cast cheap recycled-aluminium moulds in order to produce repetitive parts on the order of hundreds or more, which would otherwise cause excessive wear on a 3D Printer.

	With a [[Shredder]], the injection moulder is a core component for recycling old thermoplastics that would not be suitable for Fused Filament Fabrication type 3D Printing, such as polyethene and polypropene, which form a majority of waste plastic flows.		With a [[Shredder]], the injection moulder is a core component for recycling old thermoplastics that would not be suitable for Fused Filament Fabrication type 3D Printing, such as polyethene and polypropene, which form a majority of waste plastic flows.

4ndy: Realised 'shredder' was a more standard term for the machine I was thinking of, not chipper.

2014-06-07T10:28:46Z

Realised 'shredder' was a more standard term for the machine I was thinking of, not chipper.

← Older revision		Revision as of 10:28, 7 June 2014
Line 9:		Line 9:
	The embodied energy + wear & tear of creating a set of mould plates for production has historically limited this process to parts produced on a scale of many thousands or even millions, however, using a [[3D Printer]] and a [[Foundry]] it may be possible to cast cheap recycled-aluminium moulds in order to produce repetitive parts on the order of hundreds or more, which would otherwise cause excessive wear on a 3D Printer.		The embodied energy + wear & tear of creating a set of mould plates for production has historically limited this process to parts produced on a scale of many thousands or even millions, however, using a [[3D Printer]] and a [[Foundry]] it may be possible to cast cheap recycled-aluminium moulds in order to produce repetitive parts on the order of hundreds or more, which would otherwise cause excessive wear on a 3D Printer.

	With a [[~~Chipper~~]], the injection moulder is a core component for recycling old thermoplastics that would not be suitable for Fused Filament Fabrication type 3D Printing, such as polyethene and polypropene, which form a majority of waste plastic flows.		With a [[Shredder]], the injection moulder is a core component for recycling old thermoplastics that would not be suitable for Fused Filament Fabrication type 3D Printing, such as polyethene and polypropene, which form a majority of waste plastic flows.

	{{Video}}		{{Video}}

4ndy: I know one of you septics are going to edit this with your beloved alternative spellings, but at least I had my moment of tranquillity. ;)

2014-05-23T23:16:41Z

I know one of you septics are going to edit this with your beloved alternative spellings, but at least I had my moment of tranquillity. ;)

New page

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==Overview==

[[Image:Modified_Gingery_IM.png|thumb|Rick Sparber's Modified Gingery Injection Molder]]

The Injection Moulder enables fast production of highly repetitive/homogeneous parts such as plugs, switches, knobs, handles, etc.

The embodied energy + wear & tear of creating a set of mould plates for production has historically limited this process to parts produced on a scale of many thousands or even millions, however, using a [[3D Printer]] and a [[Foundry]] it may be possible to cast cheap recycled-aluminium moulds in order to produce repetitive parts on the order of hundreds or more, which would otherwise cause excessive wear on a 3D Printer.

With a [[Chipper]], the injection moulder is a core component for recycling old thermoplastics that would not be suitable for Fused Filament Fabrication type 3D Printing, such as polyethene and polypropene, which form a majority of waste plastic flows.

{{Video}}

<html>
<iframe width="420" height="315" src="https://www.youtube.com/embed/uD-kCf8amHk" frameborder="0" allowfullscreen></iframe>
</html>

==Detailed Description==

The Injection Moulder consists of a melt-chamber fed with chipped recycled plastic and/or pellets of virgin plastic feedstock, heated to a controlled temperature by a heater cartridge, heating resistor or some wound nichrome wire, and forced through a nozzle into a mould by a piston fitting the melt-chamber. For large moulds requiring high pressure, the piston is often driven by a motor using a leadscrew, but for small batches/parts a hand-operated lever is fine.

A simple Arduino-programmed ATMega microcontroller with a potentiometer (analogue knob) or 7-segment display & tactile switches (digital) input driving a high-voltage relay with low-frequency PID, would easily suffice for temperature control.

The melt chamber/cylinder can be made from a smooth steel pipe if you have a piston to fit it (e.g. the one shown in the video above), or from a block of aluminium with hole drilled through it using a drill press (e.g. the one in Gingery's book, and shown in Rick's document) with a 1cm thick steel rod for a piston (as can be salvaged from many discarded inkjet printers). The latter could be made with greater heating efficiency and lower material use by casting aluminium into a desired rounded shape and then reaming the melt-chamber hole to a smooth bore.

Nozzle production follows much the same theory as any RepRap 'hot-end' - having a lathe makes this much easier.

Almost any structural materials could be used for the injection moulder's frame, from recycled lumber to welded steel sections. As noted in Rick Sparber's document, attention needs to be paid to properly constraining the piston in a hand-operated lever system, so as to avoid any out-of-axis force bending the piston out of shape.

==Product Ecology==
{{Product Ecology

|Product={{Injection Molder}}

|From=
*[[Drill Press]]
*[[Lathe]]
*[[Foundry]]

|Uses=
*[[Electricity]]
*[[Plastic]]

|Creates=
*Plastic Parts

|Enables=
*Buttons, widgets, handles for machine tools...
*Replaceable-part scaffold designs, e.g. [http://www.thingiverse.com/thing:8605 this Rotary Hydroponics unit]
*Bootleg Lego ;)

|Components=
*Piston
*Cylinder
*Heater
*Controller
*Nozzle
*Lever or Leadscrew
*Moulds

}}

==OSE Project Status/Schedule==

The injection moulder project is currently in research phase. Subject matter experts are encouraged to contact us.

==See Also==
*[[Bioplastic Extruder]], for producing continuous forms such as pipes, and for very high-pressure moulds.
*The Secrets of Building a Plastic Injection Molding Machine - Vince Gingery [http://www.amazon.com/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon US], [https://www.amazon.co.uk/Secrets-Building-Plastic-Injection-Molding/dp/1878087193 Amazon UK]
*[http://rick.sparber.org/Articles/gpi.pdf A Modified Vince Gingery Plastic Injection Molding Machine] - Rick Sparber, 2010

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