High Speed Injection Molding Machines
High-Speed Injection Molding Machines for Thin-Wall & High-Cycle Production
High speed injection molding machines are engineered specifically for thin-wall packaging, medical consumables, fast-food containers, and high-volume electronics components requiring fast cycle times under 5 seconds. Standard injection units struggle with melt uniformity and dynamic response when required to inject at speeds exceeding 250 mm/s. By incorporating hydraulic accumulators, high-response servo hydraulics or full-electric drives, and reinforced mechanical structures, high-speed injection equipment delivers stable shot-to-shot consistency, reduced part weight through thin-wall capabilities, and lower unit production costs.
High Speed Injection Molding Machine Overview
To address varying factory infrastructures, energy costs, and cleanroom requirements, high-speed machines are built across three primary drive configurations:
Hydraulic Accumulator Assisted:
Utilizes a servo-pump system paired with high-pressure nitrogen accumulators. The accumulators store energy during non-injection phases and discharge instantaneously during injection, achieving high speed without requiring excessively large main pump motors.
Full-Electric Drive:
Driven by independent high-response AC servo motors for injection, plasticizing, clamping, and ejection. Delivers dynamic response, zero hydraulic oil contamination risks, cleanroom compatibility, and parallel motion capabilities for fast cycle times.
Hybrid Drive:
Combines an electric servo-driven plasticizing unit (enabling continuous recovery during mold opening) with hydraulic accumulator injection and clamping. Provides a balanced solution for high melt rates and high injection force requirements.
High Speed Injection Molding Machine Overview
High speed injection molding differs fundamentally from standard injection molding in hydraulic response, mechanical rigidity, and thermal management. Standard machines rely on pump-flow delivery, yielding injection speeds between 80 mm/s and 150 mm/s. High-speed systems utilize nitrogen-charged hydraulic accumulators or dynamic electric drives to reach injection velocities up to 800 mm/s with acceleration times under 30 milliseconds.
|
Feature |
Standard Injection Machine |
High Speed Injection Machine |
|
Injection Velocity |
80 - 150 mm/s |
300 - 800 mm/s |
|
Cycle Time Range |
15 - 60 seconds |
2.5 - 12 seconds |
|
Clamping Response |
Standard proportional valve control |
High-speed directional servo valves / linear guide toggle movement |
|
Platen Rigidity |
Standard nodular cast iron |
Finite Element Analysis (FEA) optimized heavy-duty box platens |
|
Plasticizing Drive |
Standard hydraulic motor |
High-torque servo motor with dual-layer screw cooling |
|
Primary Applications |
General industrial, automotive trim, heavy housewares |
Thin-wall containers, IML packaging, medical syringes, optical lenses |
Product List
HS-180 High Speed Packaging Series
Clamping Force: 1,800 kN (180 Ton)
Injection Velocity: Up to 500 mm/s
Tie Bar Spacing: 510 × 510 mm
Primary Application: 4-cavity thin-wall food containers, packaging lids.
HS-280 High-Cycle IML Edition
Clamping Force: 2,800 kN (280 Ton)
Injection Velocity: Up to 600 mm/s
Tie Bar Spacing: 620 × 620 mm
Primary Application: In-Mold Labeling (IML) yogurt tubs, fast-food boxes integrated with side-entry automation.
HS-380 Medical Cleanroom Spec
Clamping Force: 3,800 kN (380 Ton)
Drive Type: Full-Electric / ISO Class 7 Cleanroom Ready
Tie Bar Spacing: 720 × 720 mm
Primary Application: Multi-cavity syringe barrels, pipette tips, blood collection tubes.
HS-480 High-Precision Electronic Component Series
Clamping Force: 4,800 kN (480 Ton)
Injection Velocity: 450 mm/s with closed-loop pressure control
Tie Bar Spacing: 810 × 810 mm
Primary Application: Light-guide plates, micro-connectors, automotive optical lenses.
HS-550 Multi-Cavity Packaging System
Clamping Force: 5,500 kN (550 Ton)
Accumulator Capacity: Dual 50L high-pressure nitrogen accumulators
Tie Bar Spacing: 880 × 880 mm
Primary Application: 16-cavity and 32-cavity thin-wall drink cups, dairy containers.
HS-650 Heavy-Duty Fast-Cycle Unit
Clamping Force: 6,500 kN (650 Ton)
Platen Structure: Reinforced box platen with linear guide support on moving platen
Tie Bar Spacing: 980 × 980 mm
Primary Application: Large-format crates, logistics trays, multi-cavity industrial buckets.
Key Technical Features
Hydraulic Accumulator Injection System: Closed-loop servo valves combined with high-pressure gas accumulators enable instantaneous acceleration to max injection speed within 25 ms, maintaining linear velocity through multi-stage pressure profiles.
Rigid Box-Platen Design: Platen deformation is minimized under full clamping tonnage via Finite Element Analysis (FEA) optimization, ensuring even clamping force distribution across multi-cavity molds and prolonging mold core life.
Linear Guide Rails for Moving Platen: The moving platen rests on heavy-duty linear guide rails rather than sliding on tie bars. This eliminates tie-bar lubricant contamination and reduces friction, achieving faster movement response and enhanced alignment accuracy.
High-Torque Servo Plasticizing: Direct-drive servo motors drive screw rotation independently during mold opening and part ejection (synchronous recovery), cutting overall cycle times.
Bimetallic Screw and Barrel: Specialized screw geometries with L/D ratios of 22:1 to 24:1 feature fully flighted bimetallic cladding (tungsten carbide alloy) to handle high shear rates and abrasive additives without thermal degradation.
Real-Time Closed-Loop Controller: 0.5 ms response-time industrial controller monitors cavity pressure switches, injection position via linear optical encoders, and proportional valve feedback for continuous process regulation.
Injection Speed, Cycle Time & High-Cycle Production
High-speed injection molding requires synchronizing every phase of the molding sequence to lower total dry cycle times.
Sequence Comparison & Parallel Motion Breakdown
Standard Machine Sequence (18.0s Total Cycle):
Mold Close: 2.0s
Injection & Holding: 4.0s
Cooling & Plasticizing (Sequential): 8.0s
Mold Open: 2.5s
Part Ejection: 1.5s
High Speed Machine Sequence (4.2s Total Cycle):
Mold Close: 0.6s
Injection: 0.4s
Holding & Cooling: 2.0s (Plasticizing occurs in parallel during this phase)
Mold Open: 0.7s
IML Take-out / Ejection: 0.5s
Optimization Factors
Injection Velocity & Pressure Switchover: High injection speeds (up to 800 mm/s) fill thin wall sections (e.g., 0.4 mm wall thickness) before the polymer melt solidifies. V/P (Velocity to Pressure) switchover response times under 2 ms prevent flash and cushion variation.
Dry Cycle Optimization: High-flow proportional valves and dual-cylinder clamping mechanisms cut mechanical dry cycle times to under 1.5 seconds for mid-tonnage frames.
Parallel Motion Implementation: Ejection, core-pulling, and screw plasticizing operate concurrently during mold opening, eliminating idle phase delays.
Technical Specifications
|
Parameter / Model |
HS-180 |
HS-280 |
HS-380 |
HS-550 |
|
Clamping Force (kN) |
1,800 |
2,800 |
3,800 |
5,500 |
|
Tie Bar Clearance (H×V) (mm) |
510 × 510 |
620 × 620 |
720 × 720 |
880 × 880 |
|
Max Platen Stroke (mm) |
480 |
580 |
680 |
850 |
|
Screw Diameter (mm) |
35 / 40 |
45 / 50 |
55 / 60 |
70 / 80 |
|
L/D Ratio |
22:1 |
23:1 |
24:1 |
24:1 |
|
Max Injection Speed (mm/s) |
500 |
600 |
600 |
450 |
|
Injection Pressure (Max) (bar) |
2,200 |
2,100 |
2,000 |
1,850 |
|
Plasticizing Rate (PS) (g/s) |
32 |
58 |
92 |
145 |
|
Dry Cycle Time (s) |
1.3 |
1.6 |
1.8 |
2.4 |
|
Oil Tank Capacity (L) |
350 |
500 |
650 |
950 |
|
Machine Dimensions (L×W×H) (m) |
5.2 × 1.6 × 2.0 |
6.3 × 1.8 × 2.2 |
7.4 × 2.0 × 2.4 |
8.8 × 2.3 × 2.6 |
How to Select
Selecting the correct machine requires matching part geometry, polymer flow behavior, and automation integration:
Calculate Injection Rate & Wall Thickness
Evaluate Flow Length to Thickness Ratio (L/T Ratio).
If L/T Ratio > 150:1: Select an accumulator-assisted or full-electric configuration with injection velocity ≥400 mm/s.
If L/T Ratio ≤ 150:1: A standard high-response servo-hydraulic machine is sufficient.
Determine Required Tonnage
Calculate minimum clamping force:
Projected Area (cm2)×Material Cavity Factor (0.5−0.8 ton/cm2)=Minimum Clamping Force (Tons)
Evaluate Automation & Dry Cycle Parameters
If target cycle time is < 5 seconds or requires IML Robotics: Select a linear guide series fitted with a synchronous plasticizing motor.
If standard cycle time applies: Utilize a standard high-speed toggle clamping frame.
Key Selection Criteria
Flow Length to Thickness (L/T) Ratio:
If the part's L/T ratio exceeds 200:1 (common in 0.35 mm – 0.5 mm thin-wall containers), standard injection velocity leads to short shots. Select high-pressure accumulator models providing ≥500 mm/s velocity.
Shot Size vs. Barrel Capacity:
For high-cycle applications, shot size should ideally remain between 20% and 60% of total barrel capacity. This prevents resin degradation caused by long residence times or un-melted resin from overly rapid recovery.
Tie Bar Distance & Mold Dimensions:
Ensure adequate space between tie bars to accommodate side-entry In-Mold Labeling (IML) automation arms or high-cavity mold cooling plates.
Ejection Speed and Stroke:
Verify hydraulic or servo ejector force and speed match part drop requirements or high-speed robot extraction speeds.
Applications
Products: Margarine tubs, disposable food bowls, milk tea cups, seal lids.
Materials: High Melt Flow Index PP (MFI 30–100), PS.
Requirements: Injection speed > 400 mm/s, wall thickness down to 0.35 mm, stress-free optical clarity, fast cooling cycles.
Products: Syringe barrels, plunger rods, pipette tips, test tubes, petri dishes.
Materials: Medical-grade PP, Polycarbonate (PC), PET.
Requirements: ISO Class 7/8 cleanroom compliance, oil-free platen area, high multi-cavity weight repeatability (variation < 0.2%).
Products: Paint buckets, ice cream tubs, cosmetics containers.
Materials: PP, PE.
Requirements: Precise platen positioning accuracy (±0.05 mm) to coordinate with high-speed side-entry robot placement.
Products: Mobile phone internal frames, optical light guide plates, micro-connectors.
Materials: LCP, PBT, PA66+GF, PC.
Requirements: Closed-loop injection speed and holding pressure control to eliminate flash and warping in thin geometries.
Manufacturing & Quality Control
Factory production standards determine machine longevity, stability, and shot repeatability under continuous fast-cycling conditions.
Structural Machining: Machine bases and platens are cast from ductile iron (GGG50/GGG60) and stress-relieved via heat treatment before being machined on 5-axis CNC machining centers in a single setup. This ensures perpendicularity and parallelism within 0.03 mm.
Hydraulic Assembly & Testing: High-pressure hydraulic lines utilize hard piping with soft-seal bite-type flange fittings to prevent fluid leaks caused by high-frequency shockwaves. Nitrogen accumulator charge levels undergo 72-hour pressure drop monitoring.
Quality Inspection Equipment:
Renishaw Laser Interferometers: Calibrates platen positional accuracy, clamping repeatability, and stroke linearity.
Ultrasonic Flaw Detectors: Checks nodular cast iron platens and tie bars for internal micro-cracks or voids.
Thermal Imaging Equipment: Monitors temperature distribution across electronic components, servo drives, and hydraulic oil manifolds during load testing.
Full-Load Run-In: Every machine undergoes a minimum 48-hour continuous dry-cycle test and 12-hour full-pressure load test before shipment to verify thermal equilibrium and hydraulic stability.
Customization & OEM
Machinery designs can be tailored to meet specialized production line requirements:
Injection Unit Customization:
Custom screw geometries (barrier screws, mixing heads, corrosion-resistant coatings) for specialized materials such as PLA, PCR (Post-Consumer Recycled resin), or filled engineering compounds.
Cleanroom Adaptation:
Enclosed clamping areas, stainless steel covers, oil-free tie bar bushings, and centralized air extraction ducting for medical manufacturing setups.
Extended Mold Opening & Daylight:
Customized moving platen strokes and extended daylight options for deep-draw container molds or stack mold installations.
Automation Integration:
Factory-installed EUROMAP 67 / SPI interfaces, integrated air-blow valves, core pulls, and embedded control screens for side-entry IML automation systems.
Related Machines
Standard Servo-Hydraulic Injection Molding Machines:
Designed for general industrial parts, consumer goods, and automotive components with cycles > 15 seconds.
PET Preform Injection Systems:
Specialized high-output systems optimized for PET preforms, featuring continuous plasticizing and multi-stage cooling.
Two-Color / Multi-Component Machines:
Equipped with dual injection units for co-molded or multi-material plastic products.
Auxiliary Equipment Systems:
Dehumidifying dryers, gravimetric dosers, mold temperature controllers, and automated scrap granulators.
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