Plastic injection molding
is at the core of HBC’s operation. After
decades in the engineering business and with an
engineering infrastructure and expertise unrivalled
in the UK, we can offer extremely competitive
and cost-effective solutions. Whether thermoset
or thermoplastic, we are extremely unlikely to
be beaten on price, quality or service and are
frequently nominated in the annual Plastic Industry
Awards as a finalist.
So how do we do this? Well, having been in operation
for over 40 years, we have an engineering complex
stretching to approx. 75,000 square feet, we are
bursting at the seams with the latest technology,
we employ the very best engineers, technicians
and designers in the business, we have a plant
list which is simply world class and a workflow
which shares data across all departments. This
results in rapid production times, unsurpassed
quality and extremely cost-effective products
and services.
For further details, a quotation, or a tour of
our engineering complex with no obligation or
pressure, please call our sales team on 01293
897 200 (international: +44 (0)1293 897
200) or see our contact
page.
Precision molders & mold tooling
Precision plastic injection
molders and tooling engineers, HBC perform
the entire production process in-house. Concepts
or designs are taken through our design department,
normally using Catia V5 and Solidworks software.
Various testing phases are performed, including
Moldflow analysis. Prototypes are produced if
required, particularly for new products and inventions
which need to be tested in the marketplace prior
to full production. Once final mold tooling is
completed, production then begins in the factory
area.
After so many years in the business, HBC is in
an enviable position, with a plant list including
a huge suite of Billion, Demag, Negri Bossi, Boy
and Engel machines along with metal insert capabilities,
pad printing and assembly (including via automated
robots as well as manual), ultrasonic welding
and a full supply chain management facility -
all in-house! All HBC’s operators and machine
setters and trained by The British Polymer Training
Association and our Catia operators and designers
were trained by IBM, due particularly to the fact
that we were a key beta tester for IBM during
the application’s development. We believe
that no other engineering company in the UK can
match this pedigree, so please talk to us first
if you have a project and we will be pleased to
advise, estimate for work, or even take you around
our engineering complex so that you can see for
yourself how well placed we are for component
and parts manufacture and related assembly/engineering
services.
Our sales team can be reached on 01293 897
200 (international: +44 (0)1293 897 200)
or see our contact
page.
Custom molded parts
Plastic injection molding: the process
Custom plastic injection
molded parts and components are made by HBC
in their millions each year. We offer small batch
through to medium and large volume production
runs, as required.
So how are custom molded parts made?
After the mould design stage (all performed on
computer in our state-of-the-art dedicated design
suite) the designs are "virtually" modelled
so as to be tested on computer prior to proper
production. This includes Moldflow analysis, after
which designs are fine tuned if necessary. The
same data used in the design stage is then used
in our dedicated mold tool production department
where the metal molds are produced which will
be used in the final production process. This
is a high precision job using advanced equipment,
processes and machinery.
During the actual production process, molten plastic
is injected into the molds under high pressure.
Molds will have been carefully designed so that
on completion the components will not be locked
inside. In order to do this, sides of components
will typically not be 100% parallel with the draw
direction, which is the direction in which the
various parts of the molds are separated (molds
are normally made in at least 2 halves, called
the “core” and the “cavity”).
So, sides of components (and molds therefore)
are angled very slightly and this will be evident
if one looks closely at many household objects
and electromechanical components made using this
process. This angling is known as the “draft”.
Other, more complex, types of molds include sections
known as “slides”, which are moveable
and are inserted into the molds so as to form
particular required features which cannot be formed
using only a core and a cavity approach. On completion
they are released to allow for the component to
be removed.
The raw material which is going to make the components
and parts is usually in pellet form. It is made
into molten form using heat and shearing forces
and is then forced into the mold through channels
which allow access to the main chamber. On completion
the material will cool and solidify not only in
the mold itself but also in the channels, so forming
a frame attached to the finished component. The
frame consists of “sprues” and “runners”
(the former being parallel to the direction of
the draw, the latter being perpendicular to it
and being used to take the molten material to
the “gate(s)”, which are the point(s)
of introduction of molten material into the mold
itself. Sprues and runners are normally detached
from the finished component but can be easily
recycled. In some designs, it is possible for
the sprue and runner framework to be automatically
stripped due to the clever design of the mold
itself.
HBC Engineering Solutions can work in a large
variety of materials including many different
types of thermoset and thermoplastics, which are
selected for their properties, intended use, target
environment and material cost. A fine balance
needs to be met which addresses each of those
issues and, with a 40 year lifetime of experience
behind it, HBC are at the top of their field and
can advise where required or suggest alternatives
where worthwhile. A list of materials can be found
at this
location.
Quality is at the heart of HBC's workflow. A steady
stream of quality components can only be realised
through high quality in the design of the mold
and part, through the quality and care taken in
producing the mold and also during the molding
process itself. For instance, the molten resin
needs to be at just the right pressure and temperature
so that it can flow to all parts of the mold (this
is where the earlier Moldflow analysis at design
stage pays dividends too) so as to avoid all imperfections
in finished components. HBC has an enviable record
in this respect with the percentage of components
which are below absolute top quality being staggeringly
low at only 0.01% of the overall total produced.
If you are interested in plastic injection molding
services, would like to chat over a potential project,
need a brochure, would like to see our company DVD,
need a fast quotation or if you would like a no-pressure
tour of our engineering complex, your are very welcome
to contact us without obligation. Please call our
sales team on 01293 897 200 (international: +44 (0)1293
897 200) or use our online
contact form to outline your enquiry details if
preferred.
