How Advantageous Is Gas Assisted Injection Molding?

A brief introduction

The technique of Injection Molding is well celebrated and acknowledged worldwide by the mold

manufacturers. However, certain limitations in its traditional processes compelled engineers to drive

forth innovative measures in the way operations were implicated using the technique. This originated

the concept of Gas-assisted Injection Molding (GAIM). It is a low-pressure process that employs

nitrogen at moderate/ uniform pressure while manufacturing molds.

Gradually, the scope of the technology evolved as the most favored technique for the medical sector.

Creating abundant of possibilities to advance efficacy to numerous medical device OEMs, Gas assisted

injection molding have improved the way a PET Blow Moulding Machine would perform.

What are the highlights of the process and working principle?

The basic injection molding is at the heart of GAIM processes. The equipment suppliers provide

specific hardware and controls. By and large, improvement in the gas pressure and its flow determine

detailing of the process variables. An independent gas unit is wired with the molding machine that

process signals to regulate the operational sequence. This unit is also connected with a dedicated

nitrogen source like, nitrogen generator, tanks and bottles.

The nitrogen gas is injected within the polymer via a plain gas nozzle that enables the nitrogen gas to

flow via runners and gates before entering through the key part. Using a gas nozzle helps transfer of

gas directly to the key parts.

The benefit of using GAIM technique over conventional molding method is that the designer can

engineer larger, more-complex parts with fewer injection gates. This not only reduces resources

employment but also increases efficiency while working with complicated hot-runner systems.

Furthermore, the sections that are carved out cool down quickly which minimized the overall product

cycle time. Thus, the technology is cost effective and time efficient.

What is sequence of the process is followed?

The compressed nitrogen gas is penetrated through a network of cross-sectioned gas channels that

eventually injects the melt. Suppressed nitrogen is inert, cost-effective and widely available. Given to

the cosmetic and structural reasons, some processes make use of overspill cavities. To produce

cosmetically enhanced parts few processes require absolute filling of the tools prior to application of

compressed gas.

After gas traversing, the pressurized gas is released in the atmosphere to facilitate its recycling.

Towards the end of the process, the moulded part is ejected as soon as an ambient pressure is

formulated.

What are the reasons behind using gas based injection molding?

Apart from myriad cost related and precision related advantages of gas-assisted injection molding,

various other reasons to use the technique is as follow:

High-quality deliverables

No visible sink/resin marks found

Zero warping

Short product cycle completion

Minimized clamping force

Conclusion

Gas-assisted molding technology has evolved manifolds encompassing several other techniques. The

process stretches out to several possibilities for manufacturing parts with thick contours and

dimensions. In the absence of this technology it would be nearly impossible to incorporate part designs

due to various functional, economic and tooling reasons. Enhancing the design capabilities with

precision, gas-assisted form of injection molding has contributed greatly to the success of medical

devices. The technology has emerged as a viable tool to flag manufacturing solutions that help devise

new products uplifting the market gradually in economic terms.