Fast forward to today, and injection moulding sustainability has become crucial, with new technology, materials, and practices being developed to reduce the environmental footprint of plastic injection moulding.
In the following article, Pentagon Plastics delves further into sustainability and recycling in plastic injection moulding.
The Role of Sustainable Materials in Injection Moulding
As part of the design for manufacture stage (DFM), an evaluation is carried out into potentially using sustainable materials such as biopolymers and recycled plastics as an alternative to virgin materials. Manufacturers can lower their carbon footprint by selecting sustainable plastics derived from post-industrial or post-consumer waste for the injection moulding process. Recycled materials slash the environmental impact of plastic manufacturing and help address concerns about waste generation.
Optimising Processes to Reduce Waste
Manufacturers can reduce their environmental impact by streamlining operations and minimising waste in injection moulding. A process called cycle time – the time it takes to complete one full cycle of the injection moulding process – can be reduced. The utilisation of precision moulding techniques is another way to optimise processes. Techniques such as thin-wall moulding and micro-moulding enable the production of smaller parts, which reduces waste.
Techniques for Converting Waste into Reusable Polymer
The goal in a fully optimised injection moulding process is to minimise waste by only using the correct amount of polymer needed to fill the mould. This ensures that excess material is not consumed. In scenarios where waste is unavoidable, techniques can be used to convert the waste back into reusable polymer for future production runs. This approach reduces the environmental footprint of the manufacturing process and preserves raw materials.
Enhancing Energy Efficiency in Modern Injection Moulding Machines
Energy efficiency is a core component of sustainability in plastic injection moulding. Modern electric injection moulding machines are more energy-efficient than older models, using less power and leaving a smaller carbon impact.
Recycling in Plastic Injection Moulding
Recycling reduces the environmental impact of plastic waste. This process typically consists of collecting waste material and reprocessing it into new innovations. Plastic polymers can also be recycled when the product being made is no longer needed. High-Density Polyethylene (HDPE) and Polyethylene Terephthalate (PET) are recyclable plastics regularly used in plastic injection moulding.
The Future of Injection Moulding Sustainability
The future of sustainability in plastic injection moulding is driven by eco-friendly practices, materials, and technology. Bioplastics derived from sugarcane, corn, and starch are becoming environmentally friendly alternatives to traditional materials. Composite materials are also improving the durability and strength of moulded components for specific applications.
An important area of focus within the plastic injection moulding industry is the recyclability and reuse of plastic components to minimise waste. While challenges remain, ongoing research and advancements in bioplastics and mould tool design are assisting the industry in remaining a sustainable choice. With injection moulding sustainability continuing to evolve, manufacturers can look forward to a future where environmental impact is significantly reduced.
BOX: CNC Machining and Injection Moulding
Separately, Pentagon Plastics emphasises that CNC (computer numerical control) machining and plastic injection moulding may seem similar but operate differently. These two processes provide different applications for a variety of industries, including medical tools and consumer products.
CNC Machining
CNC machining involves pre-programming computer software to dictate the movement of machinery and factory tools. It cuts shapes from a block of material that would be impossible to achieve manually. Products made through CNC machining include:
• Art
• Jewellery
• Candle holders
• Coasters
• Board games
• Décor
• Prototype parts
• Architecture models
Injection Moulding:
Injection moulding is used for producing plastic parts and components. In this process, raw thermoplastic material is melted and injected into a mould to create an innovation. Products made through plastic injection moulding include:
• Household items: light switches, bottle caps, kitchenware, toilet seats
• Consumer goods: toys, storage containers, phone cases
• Medical devices: sterile syringes, medication trays, surgical equipment
• Automotive parts: cup holders, gear parts, dashboards
• Electronics: casings, buttons, switches
