Liquid Molding
Liquid molding is a process for molding plastic parts and components with consistent repeatable quality. It is an alternative to injection molding, which is mainly used for large parts. Liquid molding utilizes the principles of thermoplastic injection molding, but on a smaller scale. Instead of injecting hot plastic into a mold cavity, liquid molding uses a liquid thermoplastic compound with a catalyst, which is then injected into a mold. The liquid that is injected into the mold is able to flow into every corner and crevice of the part, capturing all of the fine details of the part design. Due to this level of detail, liquid molding is typically used to produce smaller parts and components such as connectors, solenoids, valves, switches and more.
Liquid molding differs from injection molding in that it utilizes a two-step process. First, the thermoplastic compound is mixed with a catalyst and then injected into the mold. This causes the thermoplastic compound to set within the mold cavity. As the thermoplastic sets, it becomes rigid and takes on the shape of the part that is being molded. After the part is set, it is then removed from the mold. This two-step process allows for a faster manufacturing cycle, as the cycle time for liquid molding is typically half the time of injection molding.
Another advantage of liquid molding is that it results in a much lower scrap rate compared to traditional injection molding. Since the thermoplastic compound is able to flow into every corner and crevice of the part, the quality of the parts is higher and there is no need for finishing operations to make the part acceptable. Additionally, there is no need for additional tooling as the liquid thermoplastic compound fills the cavities without creating excessive stress on the mold.
There are some drawbacks to liquid molding, however. One key disadvantage is the fact that it requires a specialized form of plastic that can be injected in liquid form. This can make it difficult to use certain types of plastics. Additionally, liquid molding can be more expensive than injection molding, as the liquids used for liquid molding can be very expensive.
Overall, liquid molding is a versatile and cost-effective process that can be used to produce small parts and components with highly detailed designs. It is an alternative to injection molding that offers superior quality results and a faster cycle time. While there are some drawbacks to liquid molding, it can be a great tool for producing small parts and components in a variety of industries.
