3.1) Lower Injection Pressure
Gas Assisted Injection Molding technology injects much less melting material into the mold cavity than the whole cavity volume at a time, resulting in a lower injection pressure of 10-75% of the regular injection pressure.
→Lower injection pressure results in lower residual stresses, thus minimizing warpage, The low residual stresses also improve the dimensional tolerances and stability of the product.
→Low injection pressure reduces or eliminate the flash defects.
→Low injection pressure reduces the clamping force requirement and allows smaller tonnage machines.
3.2) Save Raw Plastic Materials
The product is partially hollow, thus reducing the raw plastic material; Products produced by gas-assisted injection molding can save up to 35% of raw plastic material compared to regular injection molding, depending on the product’s shape, structure and requirements.
3.3) Improve Surface Quality
Regular injection molded products will have sink marks at the thick areas, such as behind the Rib & Boss, resulting from uneven shrinkage.
However, in the gas-assisted injection molding process, the shrinkage of the part is compensated by nitrogen gas, which makes the product shrink from the inside goes out, so the part’s surface will be in close contact with the mold and no sink marks will occur. So there will be no such marks on the cosmetic surfaces after gas-assisted injection molding.
3.4) Increase The Strength And Stiffness of The Product
Gas Assisted Injection Molding enables the uniform filling of plastic parts with large differences in wall thickness, avoiding the resulting defects of internal stress, and enhancing the strength and stiffness of plastic parts by setting up structures such as ribs with air channels.
3.5) Shorten The Molding Cycle Time
Regular injection molding, due to the thick ribs, and a lot of bosses, often requires a certain amount of injection pressure and holding pressure to ensure that the product is filled well and shaped.
However, WIth Gas Assisted Injection Molding,The product’s exterior looks like a very thick, but the interior is hollow, the cooling time is shorter than regular solid products, and the reduced holding and cooling time reduce the total cycle time.
3.6) Extend The Mold Life
Regular injection molding process in the injection process, often with very high injection speed and pressure, Make the parts and the gate around easy to have flash, and mold often needs to repair.
After with Gas Assisted Injection Molding, the injection pressure, injection holding pressure and clamping pressure are reduced at the same time, And the pressure on the mold is reduced accordingly, so the mold maintenance times is greatly reduced.
3.7) Reduce The Mechanical Wear And Tear of The Injection Molding Machine
Due to the reduction of injection pressure and clamping force, the pressure on the main parts of the injection molding machine: tie bars, toggle, plate, etc. is reduced accordingly, so the wear and tear of the main parts are reduced and the life span is extended, reducing repairs and replacements times.
3.8) Applied To Finished Products With Large Thickness Variations
the thick part can be applied as a gas channel to eliminate surface defects generated by uneven wall thickness with gas holding pressure.
Using gas-assisted injection molding allows designers to design more complex products, while mold makers can simplify mold structures. The increasing functionality of the product and the reduction in the number of components allows for shorter production cycles without the need for assembly and post-trimming work.
The production of molded CD trays and motor vehicle electronic center press-fit laminates has shown that gas-assisted injection molding can be applied to manufacture thin-walled products.
Improved dimensional stability, reduced residual stresses and reduced warpage are some major advantages of gas-assisted injection molding. The applications of gas-assisted injection molding will become more and more complex and diverse. Nowadays, gas-assisted injection molding can produce products with masses from 30g to 18kg.