High Speed Injection Molding Machine For High Cycle Production

This high-speed injection molding machine is engineered specifically for fast-cycle, high-volume manufacturing of thin-walled plastic components. Designed for demanding applications such as food packaging, medical consumables, optical components, and precision electronics, the platform combines single-cylinder/dual-cylinder high-pressure injection units with a high-rigidity toggle clamping structure.
By integrating a closed-loop servo system, nitrogen accumulator acceleration, and independent parallel hydraulic circuits, this series achieves injection speeds up to 800 mm/s and dry cycle times under 1.5 seconds. The machine eliminates thermal drift and platen deflection under continuous 24/7 heavy-duty operation, delivering repeatability within +-0.1% shot-to-shot weight deviation.

The technical parameters below represent standard configurations across our high-speed production line. Customized screw ratios and injection units are available based on mold cavitation and resin flow behavior.

High-Response Servo Injection System: Utilizes low-inertia servo drives coupled with high-flow proportional directional valves, reaching peak injection velocities in under 25 milliseconds.

Nitrogen Accumulator Assist: Integrated hydraulic accumulators supply instant hydraulic flow during the filling phase, preventing melt freezing in ultra-thin wall sections (wall thickness down to 0.35 mm).

Parallel Motion (Simultaneous Actions): Independent hydraulic circuits enable simultaneous mold opening, plasticizing, and ejection, reducing overall cycle times by 15% to 30%.

High-Rigidity Box-Platen Design: Finite Element Analysis (FEA) optimized platen design minimizes deflection under full clamping force, ensuring uniform mold stress distribution and extending mold life.

Closed-Loop Pressure & Speed Control: Digital linear optical encoders and transducer feedback loops maintain real-time pressure and position regulation, suppressing flash and short shots.

Energy-Efficient Common Bus Servo Power: Electro-hydraulic servo technology reduces power consumption by 30% to 50% compared to traditional variable-displacement pump systems.

High-speed thin-wall molding requires rapid filling before the polymer melt reaches its glass transition temperature within thin cavities.
Operational Workflow Steps
Plasticizing: Polymer resin enters via hopper and barrel, undergoing high-speed shear plasticization.
Pressure Boost: Hydraulic accumulators activate to supply immediate injection acceleration.
Cavity Injection: High-speed filling occurs under closed-loop linear optical encoder monitoring.
Parallel Operations: Plasticizing and cooling take place simultaneously alongside mold opening and part ejection.
Core System Configuration
Clamping Unit:
5-point double toggle mechanism with hardened steel bushings and automatic centralized grease lubrication.
Moving platen supported by linear guide rails to eliminate platen tilt and lower mold wear.
Sensitive low-pressure mold protection circuit to detect un-ejected parts before lockup.
Injection Unit:
Single-cylinder or balanced twin-cylinder injection structure minimizing reciprocating mass inertia.
Nitrided or bimetallic barrel and screw (specifically ratioed at 22:1 to 24:1 L/D) designed for high shear mixing and rapid plasticization.
Ceramic heater bands with PID multi-zone temperature modules maintaining +-1 degree C barrel accuracy.
Hydraulics & Control:
Dedicated high-speed controller (KEBA / Techmation) with touch-screen interface, real-time curves, and Industry 4.0 (Euromap 63/77) data interface.
High-pressure oil filtration system (3-micron rating) with oil temperature oil-water heat exchanger.

Shot-Weight Consistency: Precision servovalves monitor transition from injection to holding pressure within 1 ms, keeping mass variance below +-0.1% across multi-cavity tooling.
Reduced Stress on Mold Tooling: Platen rigidity prevents center deflection, maintaining parallel alignment within 0.05 mm even under maximum clamping loads.
Fast Hydraulic Response: High-dynamic response proportional valves shorten hydraulic signal delays, enabling instantaneous acceleration from 0 to 800 mm/s.
Extended Oil & Component Service Life: Smooth deceleration algorithms avoid hydraulic shock waves, lowering peak oil temperatures and preserving seal integrity over long continuous runs.

The standard and optional screw geometries accommodate a broad spectrum of thermoplastic resins:

Polypropylene (PP): High melt flow rate (MFR 30 - 100) resins for thin-wall packaging and containers.

Polystyrene (GPPS / HIPS): Crystal-clear cutlery, petri dishes, and rigid packaging box structures.

Polyethylene (HDPE / LLDPE): Beverage caps, closures, and flexible thin-wall tubs.

Polycarbonate (PC) & ABS: High-precision electronic housings and clear optical components.

Polyethylene Terephthalate (PET): Dedicated high-speed preform injection setups (optional high-torque motor configuration required).

Selecting the correct machine sizing requires balancing shot weight, injection rate, and clamp force against mold design parameters:
Sizing Guidelines
Clamping Force Calculation: Calculate projected area of the part including runner channels. Multiply by required cavity pressure (typically 500 - 800 bar for thin-wall PP/PS).
Injection Capacity & Flow Length: Verify the Flow Length to Thickness ratio (L/T ratio). If L/T > 150:1, an accumulator-assisted high-speed injection unit is required.
Plasticizing Rate: Ensure the screw can recover the required shot mass within the available cooling time window without degrading the melt.
Modular Configuration Matrix
Hydraulic Accumulator: Standard or expanded capacity for extreme L/T ratios.
Screw Coatings: Chrome-plated, bimetallic alloy, or tungsten carbide treatments for abrasive glass-filled or corrosive materials.
Valve Gate Control: Integrated pneumatic or hydraulic sequential valve gate controllers (4, 8, or 16 zones).
Automation Interface: Euromap 67 / SPI interfaces for side-entry robots, top-entry take-out systems, and IML automation.
Air Blow Units: Multi-circuit air ejector valves for rapid part dropping.

Every machine undergoes standardized manufacturing and verification protocols before factory release:
Structural Integrity & Machining: Machine frames and platens are cast from high-tensile ductile iron (GGG50/QT500) and stress-relieved via thermal annealing prior to CNC machining.
Component Traceability: Critical hydraulic and electrical components (e.g., Yuken/Rexroth valves, Phase/Novatar servo motors, Schneider electricals, KEBA controllers) carry full serial traceability.
Alignment & Parallels: Laser interferometers verify platen parallelism and tie bar alignment under zero and maximum load conditions.
Factory Acceptance Test (FAT): Prior to dispatch, every unit runs a continuous 48-hour dry-cycle stability test followed by a load test replicating target injection velocities and operating pressures.

We provide tailored engineering solutions to align the machine interface with existing factory automation and tooling:
Custom Screw Configurations: Specialized mixing elements, barrier screws, and vented barrels for specific additives or masterbatches.
Platen Pattern Adjustments: Non-standard EUROMAP/SPI hole patterns, custom locating ring diameters, and extended daylight distances for stack molds.
Color Matching & Branding: Custom paint finishes, client labeling, and specific safety guard door configurations.
Turnkey Packaging Cells: Complete integration including mold design, high-speed side-entry robot, mold chiller, resin dryer, and downstream vision inspection systems.

To receive a detailed technical proposal and commercial quotation, please provide the following project details:
Part Specifications: 3D CAD files (.STEP / .IGES) or physical drawings with dimensions, wall thickness, and part weight.
Resin Type: Specific polymer grade, MFR/MFI datasheet, and any filler percentages (e.g., talc, glass fiber).
Mold Details: Cavity count, mold dimensions (L x W x H), total mold weight, and runner type (cold runner or hot runner system).

Target Cycle Time & Volume: Required output per hour/day and targeted cycle time.
Auxiliary Requirements: Need for robotic automation, air blow valves, core pulls, or cleanroom compliance.