ABS Injection Molding
High heat resistance, strength, durability, and low cost make ABS a versatile material for plastic parts
Home » Capabilities » ABS Injection Molding
Erye Offer ABS Plastic Injection Molding Service Specific to Your Needs!
ABS (Acrylonitrile Butadiene Styrene) is a widely used thermoplastic polymer known for its toughness, strength, and ability to withstand impact. It's a popular material in many industries, including automotive, electronics, and consumer goods.
At Erye, we specialize in ABS injection molding, offering precision manufacturing services to produce high-quality, durable parts tailored to your needs.- Low-volume and high-volume production
- Small to large part size
- Free & fast DFM report
- No mininum order quantities
- T1 samples as fast as 10 days
ABS Plastic Molding Design Guidelines
Following are the key design elements that impact both the manufacturing process and the performance of the final ABS molded product.
| Item | Description |
|---|---|
| Wall Thickness | Recommended Thickness: 2-4 mm (0.08-0.16 inches). Use ribs to strengthen thin walls, keeping their thickness 50-60% of the main wall. |
| Draft Angles | To ensure smooth ejection from the mold, parts should have a draft angle 1-2° for most features. For textured surfaces, increase to 3-5°. |
| Radii and Corner | Avoid sharp corners to reduce stress concentrations, use a minimum radius of 0.5-1 mm (0.02-0.04 inches) for corners. |
| Shrinkage | ABS typically shrinks 0.4-0.7% during cooling, account for shrinkage in part dimensions and mold design. |
| Undercut | Design parts to minimize undercuts, use side actions, lifters, or collapsible cores if undercuts are unavoidable. |
| Surface Finish | ABS can be molded with various surface finishes, from glossy to matte, it also can be painted, chromed, or textured for enhanced aesthetics. |
ABS Molded Material Properties
Like other injection molded plastics, ABS has typical material properties. The following table lists general ABS grade material properties.
| Property | Description | Value/Range |
|---|---|---|
| Mechanical Properties | ||
| Impact Resistance | Good toughness and resistance to impact forces. | High |
| Tensile Strength | Measures the force required to pull the material to its breaking point. | Typically 20-45 MPa (2900-6500 psi) |
| Flexural Strength | Measures the ability to resist bending under load. | Typically 40-80 MPa (5800-11600 psi) |
| Thermal Properties | ||
| Glass Transition Temperature (Tg) | Temperature at which the material transitions from a hard, glassy state to a more rubbery state. | ~105°C (221°F) |
| Operating Temperature Range | The range of temperatures within which the material maintains its structural integrity and performance. | -20°C to 80°C (-4°F to 176°F) |
| Heat Deflection Temperature | Measure of a polymer's resistance to distortion under a specified load at elevated temperatures. | 81°C at 1.81 MPa |
| Melting Point | ABS is amorphous and does not have a true melting point. | 217-237°C |
| Electrical Properties | ||
| Electrical Insulation | Ability to prevent electrical current flow, making it suitable for electrical enclosures and components. | Good |
| Chemical Properties | ||
| Chemical Resistance | Resistance to various chemicals. | Good resistance to diluted acids and alkalis; moderate resistance to aliphatic hydrocarbons; poor resistance to aromatic hydrocarbons and alcohols. |
Advantages of Choosing ABS Molding
Custom ABS Plastic Molding Application
Automotive Industry
- Dashboards
- Interior trim
- Knobs and buttons on the dashboard
- Door handles
- Mirror housings
Consumer Electronics
- Smartphone cases
- Computer housings
- Keyboards
- Mouse enclosures
- Tablet cases
- Remote control housings
Toys Industry
- Action figures
- Board game pieces
- Toy vehicles
- Puzzle pieces
- Toy guns and accessories
Sporting Goods
- Bicycle parts
- Helmets
- Ski poles
- Fitness equipment enclosures
- Golf club heads
Additonal Options for ABS Parts
ABS Plastic Manufacturing Guide
ABS Injection Molding Process
- Material Pre-treatment: ABS resins tend to absorb moisture, so they must be dried before processing. General-grade ABS should be baked at 80-85°C for 2-4 hours or treated in a dry hopper at 80°C for 1-2 hours to restrict the moisture content to less than 0.1%. For heat-resistant ABS with PC components, the drying temperature may need to be adjusted up to 100°C.
- Melting the ABS: ABS plastic pellets are melted into a moldable state. The melting temperature typically ranges from 200 to 280°C. Injection temperatures usually range from 200 to 230°C, but caution is needed to avoid excessive heat, which can lead to plastic decomposition.
- Injecting into the Mold: The molten ABS is then injected into the mold cavity. The injection pressure generally falls within the range of 50-100 MPa. Screw-type injection molding machines are commonly used, with each injection volume being 50-75% of the equipment’s maximum injection volume.
- Fill, Pack, and Hold Stages: The injection molding process consists of three critical stages:
- Fill stage: About 95-98% of the ABS material is injected into the mold.
- Pack stage: Pressure is adjusted to inject more ABS material into the mold to account for shrinkage and backflow.
- Hold stage: The material is held at a fixed pressure until the cooling process begins.
- Cooling: Once the mold is filled, the molten plastic solidifies and cools to take the shape of the mold. Inadequate cooling can lead to surface imperfections, so properly designed wall thickness and an improved cooling system are vital. For parts with large projection areas, the fixed mold temperature should be 70-80°C, and the moving mold temperature should be 50-60°C.
- Ejection and Reset: After the part has fully cooled, the mold sides open to eject the part. The mold parts are then reset to begin the process again.
Several factors must be considered during the ABS injection molding process, including wall thickness, shrinkage rate, stress concentration, melt temperature, injection pressure, injection molding speed, and cooling rate. Maintaining uniform wall thickness is important to avoid stress on the plastic part. The injection speed should also be adjusted to enhance surface quality, as an overly low speed can result in insufficient plastic density and poor gloss.
Pre-treatment of the material, selection of appropriate process parameters, and careful mold design contribute to a reliable and repeatable injection molding process for ABS parts. For complex ABS product molds, a series of processing technologies such as CNC milling, EDM, deep hole drilling, lathe, grinding machine, wire-electrode cutting, CMM, and polishing may be used.
Consideration During ABS Injection Molding Process
- Material Drying: Properly dry ABS pellets to remove moisture, as trapped water can lead to defects such as bubbles and surface imperfections.
- Molding Machine Setup: Calibrate machine settings, including temperature, pressure, and injection speed, based on the specific characteristics of ABS.
- Injection Pressure and Speed: Adjust injection pressure (typically 50-150 MPa) and speed to ensure thorough filling of the mold without defects like short shots.
- Temperature Control: Maintain precise control over barrel and mold temperatures. Barrel temperatures generally range from 200 to 230°C, while mold temperatures are typically set between 50 and 80°C.
- Cooling Rate: Optimize cooling rates to prevent warping or shrinkage and ensure uniform solidification of the part.
- Wall Thickness and Design: Design molds with appropriate wall thickness, draft angles, and venting to avoid defects like warping or flash.
- Shrinkage Management: Understand the material’s shrinkage characteristics to design mold cavities that ensure accurate final dimensions.
- Cycle Time: Balance efficient cycle times with adequate cooling periods to maintain part quality while maximizing productivity.
- Quality Control: Implement quality checks throughout the process to quickly identify and rectify issues, ensuring consistency in production.
- Post-Processing Considerations: Plan for any necessary post-processing steps, such as trimming or surface finishing, to achieve the desired product quality.
Have a Question?
