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In the plastic molding process, a thermoplastic resin is melted and then forced (injected) into a mold containing one or more cavities. After this molten plastic cools and the polymer solidifies, the parts are removed (ejected) from the mold. Injection molding facilitates mass production of high-precision, three-dimensional plastic parts [1]. Injection molding is one of the most commonly-used plastics manufacturing processes. It can yield parts weighing as little as a fraction of a gram to as much as 150 kg [2]. Currently, 30% of polymeric resins [3] - of which 90% are thermoplastics (i.e., capable of being remolded) – are consumed in plastic injection molding. This process makes it possible to produce parts characterized by: 1). Great complexity; 2). Good surface appearance; 3). Precision of small details; 3). Precise wall thickness and otherwise excellent dimensional stability; and 4). No necessity for subsequent finishing work.

There are five important factors in the injection molding process:

1). The injection-molding machine

2). The mold

3). The material

4). The method

5). The operator.

While each of these factors has a potential for variation, this discussion is limited to single-stage reciprocating screw injection machines and the flow of therm oplastic polymer melts in two-plate cold runner molds.

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