What is Vertical Injection Molding?

Vertical injection molding is a specialized process where the mold opens and closes on a vertical axis. This technique is particularly beneficial for overmolding inserts, as gravity aids in accurately placing the inserts into the mold cavities. Vertical presses can be ideal for producing parts that require insert molding, improving efficiency and precision in manufacturing. 

 

Comparing Vertical and Horizontal Injection Molding

Vertical Injection Molding: Uses a vertically oriented mold, which is beneficial for insert molding due to gravity assisting with placement. It is often used for applications requiring high precision and insert overmolding. 

Horizontal Injection Molding: The traditional method where the mold operates on a horizontal plane. It is widely used for general-purpose injection molding and is suitable for a variety of part designs and sizes. 

 

Advantages of Vertical Injection Molding

  1. Space Efficiency and Flexibility: 
    • Smaller footprint suitable for limited floor space. 
    • Easier mold changes and accessibility, resulting in faster setup times and increased production efficiency. 
    • Can accommodate multiple molds simultaneously, optimizing productivity. 
  2. Enhanced Precision and Quality: 
    • Precise control over the injection process for consistent, accurate molding of complex parts. 
    • Better control of mold alignment, reducing part defects and improving product quality. 
    • Gravity-based feeding system ensures consistent material flow and shot size, resulting in high-quality parts. 
  3. Versatility and Customization: 
    • Suitable for a wide range of processes including insert molding, over-molding, and multi-component molding. 
    • Ability to incorporate rotary tables and robotic arms for automated processes, enhancing post-molding operations and production capabilities. 
  4. Cost-Effective Solution: 
    • Smaller size requires less floor space, reducing facility costs. 
    • Efficient use of material and energy, along with faster setup times and increased productivity, contributing to overall cost savings. 

 

Industry Applications of Vertical Injection Molding 

Vertical injection molding is essential across various industries, including medical device manufacturing, automotive production, and consumer electronics. This versatile process offers precision and efficiency, making it ideal for producing intricate components in these sectors. 

 

Precision in Medical Device Manufacturing

The medical sector has embraced the high standards of precision offered by vertical injection molding, particularly with insert molding. This process can hold tight tolerances and offers design flexibility, making it ideal for medical components like cannulas, tubing, wires, and delicate sensors. Vertical injection molding machines allow for quicker cycle times and the use of multiple molds simultaneously, enhancing efficiency. 

Vertical injection molding is favored for its ability to mold delicate components directly into devices, reducing the need for post-molding operations like machining, gluing, or ultrasonic welding. The process ensures precise and consistent alignment, which is critical for producing high-quality medical devices. 

Overmolding, a subset of insert molding, is also commonly used. This process involves molding a second layer over an initial insert, adding functionality and complexity to the medical devices. 

In fact, Wright Engineered Plastics, a Seaway Plastics company, recently partnered with a leading global healthcare company to address production challenges for a critical medical device. Initially, using an older vertical injection molding press resulted in low yield and inconsistency, with only 30%-40% of parts meeting the customer’s quality standards. After investing in a new vertical injection molding press, Wright significantly enhanced the process, achieving an 83% success rate. This improvement not only reduced waste but also lowered production costs, reinforcing Wright’s commitment to quality and innovation in medical device manufacturing. For a detailed look at this success story, read the full case study here. 

For medical device engineers, partnering with a capable vertical molding manufacturer is essential to keep manufacturing efficient and cost-effective, ensuring innovative solutions reach patients safely and swiftly. 

 

Wright Engineered Plastics: Your Partner in Advanced Manufacturing

Wright excels in vertical injection molding. Their brand-new Arburg press, coupled with vision systems, including cameras, laser detectors, and limit switches, prevent misplacement and mold damage, ensuring consistent quality. They serve diverse industries with a focus on improving efficiency, reducing defects, and enhancing product performance. For more information on their vertical injection molding services and how they can assist with your next project, please contact Wright Engineered Plastics today. 

 

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