It’s a big challenge to achieve color consistency for large production runs of plastic injection molded parts. To ensure consistency when molding colors, it’s essential that you have careful process control at every step.

It’s important to note that plastic color is highly subjective – subjective in how you see and interpret plastic color. It depends on viewing conditions, visual acuity, the light source, and many other variables.

• Color Consistency Challenges During Injection Molding Process
• The Importance Of Pantone
• What Is Masterbatch And Its Importance
• Achieving Consistent Colors For Low Volumes
• Molding Custom Colors in High Volume Injection Molding

In this Serious Engineering video, learn what color is and how we measure and control molding colors during manufacturing.

Color Consistency Challenges During Injection Molding Process

The volume of parts is the most important factor affecting the consistency of molding colors.

Why is this important? It’s important because plastic resin suppliers typically have minimum order quantities that apply to pre-compounded resins. These MOQ restrictions can affect a product developer’s decision about the smartest way to prepare colors for plastics.

Some coloring processes that are fine for small batch orders wouldn’t work for large-scale production.

The Importance Of Pantone

Pantone plastic color charts and plastic color chips are important tools used to measure and prepare molding colors. Pantone is the industry leader in making plastic color chips to help design professionals mix, match, and measure liquid colors for plastics.

The great value of Pantone color chip samples is the standard reference numbers that take all the guesswork out of the process. Although they have thousands of standard reference colors, be aware there are millions of colors out there.

That’s why other systems and color reference charts are also used.

What Is Masterbatch And Its Importance

‘Masterbatch’ refers to a highly concentrated pigment that’s used to make large volumes of colored plastic injection molding resin.

Plastic masterbatch pigment is mixed at a ratio of one part of color masterbatch to 24 parts of the base material. This means that a little masterbatch goes a long way.

And, since it’s sold in minimum order quantities of two metric tons, this represents a very large number of finished parts.

Achieving Consistent Colors For Low Volumes

For low-volume production runs, there are three standard methods for preparing colored resins.

1. Use a predefined or “stock” color

Pantone or RAL colors are easily available and consistent among all suppliers. If you give us a Pantone number, or a similar color matching system, we can make sure you get exactly the color you want.

2. Customer supplied material

If you’re able to provide your own resin, you will get the color you want. But we must have enough material to fulfill the order.

3. Use pre-formulated resin

Material compounders sometimes have leftover stock in custom colors that they can’t otherwise sell. If the customer approves the color choices available, then it may be one way to ensure consistency without needing to make a special order.

Given that we can order the right material for your desired Pantone or RAL color, we can achieve fairly consistent color matching per batch. In between production batches, you may face slight color alterations, but they’re insignificant.

Achieving 100% Color Matching Within An Assembly

In some cases, injection molded parts need to match perfectly. For example, in an assembly where two or more pieces are fitted together. To ensure color consistency, we use a family mold or we paint them after molding.

1. Family Molds

A family mold is a multi-cavity tool that makes all of the parts of an assembly in one cycle. The benefit of a family mold is that the parts are guaranteed to match. But the challenge here is designing the mold so it fills evenly despite the different part shapes. Such a mold will probably need sequential valve gating which adds cost and complexity.

That’s why this solution is not economically viable for small production runs.

2. Painting

Painting is another option. You will want to use a paint color that is very close to the base material so that small scratches won’t show.

Molding Custom Colors

There are three ways to make custom colors for plastic injection molded parts.

For low volumes, only the first option makes economic sense, but in that case, achieving color consistency will be very difficult. Alternately, using compound custom material, or using a masterbatch colorant, allows color consistency within batches.

But these methods are only suited for larger production volumes, as we describe below.

• Use pigments in the hopper (low-volume)
• Purchase custom compound material (high-volume)
• Use a masterbatch colorant (very high-volume)

Using Pigments In The Hopper And The Challenge Of Color Consistency

In this method, uncolored plastic pellets are mixed with colored pigment in the machine hopper before the resin is injected. Product developers should know that there are still some compromises when using this method.

1. Inconsistent mixing of pigment

Uncolored granules are mixed with pigment powder in a rotating drum. Electrostatic attraction is the only force keeping the two materials together. That’s why it’s impossible to guarantee 100% consistent coloring of the granulate.

2. Pigmenting powder spots

Pigmenting powder is naturally very thin. For this reason, it can sometimes burn as it’s heated, and this will show up as black spots on the finished parts.

3. Humidity

Most plastic resins need to be dried in a special drier before pigments can be added.

During this process, it’s possible that the raw pellets will reabsorb some atmospheric moisture and this can contaminate the mixture. That’s why it’s important to use a sealed system – from the drier to the hopper to the machine barrel – to prevent the introduction of moisture.

Despite these molding challenges, there are still perfectly sound reasons why product developers may opt for mixing colors in the hopper.

4. Advantages

There are many advantages to using this method including the minimum cost for coloring and low volumes of custom colors.

Molding Custom Colors in High Volume Injection Molding

There are two ways to achieve color consistency for high volumes of molded-in colors. Below we’ll discuss the advantages of pre-mixed compounded material and using a masterbatch colorant.

Compounded Colors

It’s possible to order custom colors directly from the raw material supplier, but they have a minimum purchase requirement of one metric ton of resin. This represents a lot of finished parts, but production can be spread out over many different batches so the material won’t go to waste.

Advantages

• Custom colors can be ordered
• Fair color consistency

Disadvantages

• Only suitable for high volumes
• Minimum 1.02 tons of finished parts
• Higher cost for compounding per kg

Using Masterbatch Colorant

Masterbatch pigment is a highly concentrated colorant that’s added to the resin just before it’s mixed into the machine. The mixing ratio of uncolored pellets to masterbatch is 24:1. This yields a very consistent and uniform result for maximum throughput. However, the downside is that masterbatch pigment can only be purchased in volumes of 2 tons minimum.

That represents 50 tons of finished parts, so clearly this approach is suitable only for the highest volumes.

Advantages

• Lowest cost for compounding per kg.
• Good color consistency within the batch

Disadvantages

• Only suitable for very high volumes
• Minimum 50 tons of finished parts
• Slight color variations between batches”

Ready to start your project? Request a free quote from our team.

If you liked reading this article, we recommend the following content:

• Plastic Injection Molding Services
• Maintaining Color Consistency in Plastic Injection Molding
• Molding Defects: The Top 5 Plastic Injection Molding Defects (and How to Solve Them)

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Features:

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• Microelastic elasticated inserts
• Pre-curved fingers
• Tightening strap
• Aramid fiber stitching
• Drum-dyed goatskin leather super soft palm
• Goatskin Leather
• DCP system on little finger
• Ergonomic PU knuckles protection base
• One single leather panel to the side of the hand
• Pro-Hand
• Reinforced leather palm
• Titanium Pro-tek knuckles
• TPU sliders to protect the finger’s joints
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• Gloves certified to CE Cat. II – Pr-EN 13594 Standard lev. 2.

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Basic Info.

Model NO.
DB-01

Material
Ultra Plush Fabrics

Age Group
Adults

Feature
Anti-Pilling, Portable, Wearable

Type
Blended Blanket

Knitting Method
Machine Weaved

Pattern
Plain Color

Usage
Home, Hotel

Transport Package
Non-Woven Bag

Specification
Normal size and customized size

Trademark
DELO

Origin
Anhui China

HS Code
9404909000

Production Capacity
10000

Product Description

The use of additive manufacturing applications is on the rise, with the market value expected to increase from $6 billion in 2017 to nearly $26 billion by 2022. The advantage of additive manufacturing comes from creating complex structures that vary in complexity, customization, lightweight, strength, and speed. As additive manufacturing for medical devices continues to gain momentum, there are five main areas where we are seeing the most growth opportunity from this evolving technology.

Let’s take a look at how the capabilities of additive manufacturing have become the de facto method of production in these industries.

Dentistry

The largest market for additive manufacturing in medicine right now is dentistry and related orthodontics such as bridges, crowns, braces, and dentures. Currently, digital dentistry is a $2.5 billion industry and this is set to more than double in a few years. Digital dentistry is more of a workflow than a single technology. This process typically begins with a scannable model or impression that’s subsequently converted into 3D digital data.

Many 3D-printed dental appliances are easily customized for a precise fit while also being printable in a variety of substrates, from flexible polymers to rigid titanium.

There are also specialized printers configured to use the dental scanning software, along with biocompatible resins, that can fit in small offices and clinics for immediate, on-the-spot solutions ready in a single day.

Anatomical Models

The human body is complex and each is unique. Therefore, when doctors and clinicians need to consider individual treatments, it helps enormously to see an accurate model of the subject in question – whether that’s a bone, an organ, a tumor, or a limb.

Luckily, this is now a reality. Great strides have been made in medical imaging technology, including highly accurate full-color 3D scanning down to the vascular level. Using this data, along with sophisticated topological mapping software such as Mimics®from Materialise, biomedical engineers can use 3D printers to create realistic models for analysis.

From these models, doctors can then devise surgical strategies like where to make incisions. Also, models assembled from multiple pieces can be disassembled to reveal structures within that might otherwise have been blocked from a surgeon’s view. The number of hospitals in the United States with a centralized 3D printing facility has grown exponentially, from three in 2010 to more than 100 by 2019.

General Tools

This is a broad category of auxiliary equipment that would be expensive and time-consuming to develop in smaller volumes. It includes clamps or grips designed for an individual patient’s anatomy, possibly to aid in examinations, treatments, or surgical procedures.

Additive manufacturing applications are also being used in many developing countries to design non-specific clamps, catheters, and other fittings that are fast and economical to produce on the spot as needed.

Prosthetics and Orthotics

Additive manufacturing technology has helped expand patient options for prosthetics and orthotics in terms of fit, function, and aesthetic. A prosthetic can be a replacement of a body part, either internally (i.e., hip joint) or externally (i.e., a missing limb).

Traditionally, prosthetic limbs were inadequate in their customization options. They were either limited in their functionality or incredibly expensive, requiring a lot of measurement, test fitting, and hand-craftsmanship that is inaccessible to many people. This is especially true in remote areas or regions experiencing military conflict, where such prosthetics are in high demand.

Orthotics are also custom pieces, made to assist the wearer’s bone structure with extra support or by correcting misalignment issues. Using modern polymers, 3D printed plastic orthotics are strong, lightweight, durable, and also pliable for added comfort. They can also help mitigate foot pain caused by conditions such as diabetes, arthritis, or plantar fasciitis.

Health Monitoring and Drug Delivery

Another advantage of additive manufacturing for medical devices is the ability to make complex micro gadgets that work inside the body to deliver medicine or to monitor a patient’s health.

MIT, in conjunction with Harvard’s Brigham and Women’s Hospital, has developed an ingestible device that can remain in the stomach for a month. Self-powered, it delivers discrete amounts of drugs for patients requiring long-term care, including those who require treatment for cancer or HIV. This device is currently in the testing stage, but it represents the kind of approach that many other researchers are trying to refine.

Such micro devices will soon be able to transmit data wirelessly to an external medical wearable for detailed health monitoring. Other printed sensors can be injected into the bloodstream to provide active monitoring of blood glucose levels, blood oxygenation, and other critical metrics that doctors will use to quickly respond to a patient’s medical condition.

These are just a few of the amazing applications being made with this transformative additive manufacturing technology.

If you liked reading this article, we recommend the following content:

• Medical injection molding
• Benefits of CNC machining for medical
• Micro molding medical devices
• Metals used in medicine

The advancement of manufacturing technologies has been pivotal to the semiconductor industry’s growth in the last two decades. Today, several types of state-of-the-art machines exist, including high-speed CNC machines and 3D printers, capable of manufacturing a wide range of semiconductor products.

But just because these machines simplify semiconductor machining, it doesn’t mean that manufacturing semiconductor components is any less complex than it used to be. A lot of work and effort goes into creating semiconductor products accurately and precisely.

In this article, we’ll present four things you need to understand about semiconductor machining. This article is a must-read if you plan to set up a semiconductor manufacturing facility or you’re looking to outsource semiconductor machining to a third-party machine shop.

#1 Semiconductor Designs are Becoming Complex and More Challenging to Manufacture

A typical wafer can be as small as 150 mm in diameter, housing hundreds of semiconductor chips that require the highest machining accuracy and tightest tolerances. A small dent or hairline fracture in your wafer can render your semiconductor parts useless.

Modern-day CNC machines play a vital role in semiconductor machining. For example, CNC milling machines allow you to achieve minimum tolerances on surface finishes and flatness and dimensional precision of regular semiconductor designs. CNC turning machines also enable you to create cylindrical semiconductor components while meeting the tolerance requirements on circularity and cylindricity.

But that’s not all there is to the challenges in semiconductor machining.

Silicon — one of the most commonly used materials in integrated circuits and other semiconductor products — is exceptionally challenging to manufacture due to its semi-crystalline nature. This material demands a high level of caution and machining expertise to create the parts you need accurately. (Related Post: CNC Machining Materials: Making the Best Choice for Your Project)

#2 Pre-Machined Pieces are helping Machine Shops to Manage Supplies

As technology has advanced, semiconductors have spread from just computers and cars to pretty much any electronic product you lay your hands on. While this is good news for many semiconductor manufacturers, it’s one of the primary reasons why the demand for chips has continued to outstrip supply in recent years.

Semiconductor manufacturers have been tackling this dynamic demand and meeting the high volume needs of their customers by creating what are known as pre-machined pieces (or machine-ready blanks).

As the name suggests, pre-machined pieces are raw material pieces that have been cut and pre-milled according to standard semiconductor component shapes and sizes. The goal is to reduce the amount of machining (or setup) required to create customer-specific parts.

#3 Smarter Processes are Helping to move Semiconductor Machining into the Future

Predictive diagnostics and artificial intelligence have completely revolutionized semiconductor manufacturing processes. Modern-day semiconductor machining technologies are installed with sensors that monitor critical operation parameters like cutting speed, voltage, and temperature, to name a few.

The data from these sensors are fed through an intelligent system that checks for accuracy, precision, and dips in quality. This allows semiconductor manufacturers to spot design (or manufacturing) flaws early, reducing the likelihood of downtimes and potential semiconductor machining failures.

What’s more, top-tier machine shops automate some of the machining duties that human workers would otherwise handle through advanced collaborative robots—they work alongside human operators (or machinists) to perform manufacturing operations. So, for example, you can set up these robots to handle repetitive tasks like cleaning CNC machined parts or transporting wafers from one machine to another.

These robots allow you to improve operational safety and productivity while ensuring high-quality semiconductor parts.

#4 Applications of CNC Machining in the Semiconductor Industry

Today, CNC machining plays a vital role in almost every industry you can mention, including the semiconductor and electronic industries (Related Post: Exciting Applications of CNC Machining in 8 Top Industries).

To give you an idea of the versatility of CNC machines in the semiconductor industry, here are some of the parts you can manufacture using CNC machines:

• Gaskets and seals
• Electronic circuits
• Sockets
• Gas distribution plates
• Wafer chucks
• Computer chips
• Insulators
• Solder pad stencils
• Flex circuit stiffeners

One thing to note, though: these parts are incredibly complex, requiring high accuracy and tolerances as tight as 4μm to fit into electronic devices. The success of your semiconductor device manufacturing project primarily depends on the machine shop you work with.

Semiconductor Machining Services: Gensun Precision Machining Can Help

Gensun Precision Machining is a leading provider of cost-effective semiconductor machining services across the globe. We’ve been in business for over a decade, helping our customers to produce and ship high-quality semiconductor parts consistently and on time.

Whether you need low-volume semiconductor prototypes or high-volume production, our service is second to none. We have state-of-the-art machining equipment, highly experienced machinists and engineers, and a dedicated quality control team to ensure that your parts get done right every time.

Reach out and tell us about your project and let our team help you create the precision machined parts you need.

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