In the injection molding industry, especially when dealing with special materials and large-sized products, there are significant hidden costs and challenges. Many might not realize that injection molding is not just a simple production process; it involves substantial preparation, adjustments, and fine-tuning to ensure product quality and stability. This is particularly true during the trial production phase, where factories face tremendous pressure.
- The Challenges of Special Materials
Special materials, such as high-temperature resistant, glass fiber-filled resins, or other functional plastics, often have higher melting points and poor flow properties. These characteristics require more precise temperature control and injection force during the molding process.
These materials also have higher purchase and processing costs, and the equipment needs to be more specialized and fine-tuned.
2. The Complexity of Large-Size Products
For larger products, the choice and adjustment of injection molding machines become more complex. Large machines not only consume more energy and require more maintenance, but they also need more time to ensure stable operation.
As product size increases, mold design and manufacturing become more complicated, often requiring multiple modifications and adjustments.
3. The Cost of Trial Production
During the trial production phase, significant amounts of raw materials are consumed to adjust the machine parameters. For special materials, each adjustment and optimization can lead to material wastage.
Given the complexity of these products, the adjustment period can last anywhere from half a day to an entire day. This time, coupled with material loss, results in higher production costs.
4. High Labor and Equipment Costs
Injection molding factories not only invest substantial manpower for machine adjustments and production, but labor costs for operators and engineers are also rising.
The use and maintenance of large machines require significant investment, and the operational costs for these machines directly impact product pricing.
5. The Dilemma of Small Trial Orders
When dealing with small trial orders, the efficiency of the production line decreases significantly. Due to the high costs of injection molding and the extensive time needed for adjustments, small orders are typically not profitable. The factory often ends up assisting clients with small-batch market testing.
Small-batch production not only hampers overall production control but, from an economic standpoint, often cannot cover costs, leaving factories with little to no profit.
Faced with these challenges, injection molding factories must not only manage high costs but also focus on fine-tuning production control to maximize efficiency and minimize waste. Clients need to understand that during the production of special materials and large-size products, reasonable production costs and time investments are essential to ensure product quality and market demand.
