Calculate Injection Molding

You can use the Calculate Injection Molding cost model to calculate the process times and costs for the injection molding manufacturing process in plastics processing. In FACTON, there are value rule tables and formulas defined at the cost model providing you with information on:

  • the anticipated cycle time,
  • the possible process output per time and cycle,
  • the material consumption,
  • the clamping force and the shot volume of the machine, and
  • the primary and secondary processing times.

The table shows typical application scenarios of the cost model for parts and industry:

Typical Parts Typical Industries
  • Toys / Tools
  • Packaging / Containers
  • Furniture / Furnishings
  • Panel Systems in Cars
  • Automotive Sector / Aerospace Sector
  • Electrical Industry
  • Food Processing Industry
  • Consumer Goods / Everyday Items
Note

You need knowledge of the Injection Molding manufacturing process in order to use the cost model.

Sequence

The following example illustrates the process and structure of the Injection Molding cost model:

Hint

The black triangle ◣ helps you identify editable values.

The Consistency Rule Violation check is available to you when entering values. The consistency rule violations check notifies when there are missing values and verifies the accuracy of the values entered.

When you hover over one of the Consistency rule violations icons with your mouse, a tooltip appears with the specific reason for the consistency rule violations.

 

Step 1: Create Should Cost Calculation

Further Information > Create Should Cost Calculation

 

Step 2: Insert Part

  1. Select the should cost calculation in the Structure view.

  2. In the ribbon, click on Edit > Insert > Part (Piece).

    A part is inserted into the calculation structure.

  3. Define the following properties in the Details view (General Properties view schema):
    4. Material Classification* Basic Material > Plastic Material > Thermoplast > ABS - Acrylnitril-Buthadiene-Styrene
    Manufacturing Method* Primary Shaping > Casting > Injection Molding
    *FACTON recommends the matching materials and machines according to your choices in the material classification and manufacturing method.
Note

You can use the following material classification with the cost model:

For Thermoplast (Basic Materials > Plastic Material > Thermoplast):

  • PE - Polyethylene > PE-HD - Polyethylene high density
  • PE - Polyethylene > PE-HD - Polyethylene low density
  • PP - Polypropylene
  • PA - Polyamide > PA 6 - Polyamide 6
  • PA - Polyamide > PA 66 - Polyamide 66
  • PA - Polyamide > PA 11 - Polyamide 11
  • PA - Polyamide > PA 12 - Polyamide 12
  • PS - Polystyrene
  • ABS - Acrylnitrile-Buthadiene-Styrene
  • SAN - Styrene-Acrylnitrile
  • ASA - Acrylonitrile Styrene Acrylate
  • PC - Polycarbonate
  • PC / ABS - Polycarbonate/Acrylnitrile Buthadiene Styrene
  • PVC - Polyvinylchloride > PVC-U - Polyvinylchloride Unplasticized (hard)
  • PVC - Polyvinylchloride > PVC-P - Polyvinylchloride Plasticized (soft)
  • PMMA - Polymethyl methacrylate
  • PET - Polyethylene terephthalate
  • PBT - Polybutylene terephthalate
  • POM - Polyoxymethylene
  • PPE/PA - Polyphenylene ether/Polyamide
  • PSU - Polysulfone
  • PES - Polyethersulfone
  • CA - Cellulose acetate
  • CP - Cellulose proprionate
  • CAP - Cellulose acetopropionate
  • CAB - Cellulose acetobutyrate
  • PTFE - Polytetrafluoroethylene
  • ETFE - Ethylene tetrafluorethylene
  • FEP - Tetrafluorethylene/Hexafluorpropylene
  • PCTFE - Polychlortrifluorethylene

For Elastomers (Basic Materials > Plastic Material > Elastomer):

  • EVA - Ethylene Vinyl Acetate

 

Step 3: Insert Process

  1. Select the part in the Structure view.

  2. In the ribbon, click on Edit > Insert > Process.

    A process is inserted in the calculation structure.

  3. In the Details view (Calculation view schema ), select the manufacturing valuation Calculate Thermoplastic Injection Molding.

    The process is automatically renamed to "Injection Molding".

    A new group Manufacturing Valuation appears with sub-groups.

  4. In the Details view, click on the filter symbol and activate the checkbox for the values to be entered.

  5. For example, enter the following values:

    Input parameters
    Runner Type Hot Runner
    Cavity Count selected 2.00 pc/cycle
    Component 1
    Material Classification

    is automatically assumed from the part
    Material Selection

    ABS - Granules

    After selecting, the density and other material parameters are shown.
    Part (Component) Weight 0.1 kg/pc
    Projected Area of Part 50 cm²/pc
    Maximum Wall Thickness 3 mm
       
    Machine Selection

    A matching machine is being determined based on the calculated values for clamping force and shot volume.

    You can also choose a different machine from the combobox.
    Labor Group

    EG05

    The corresponding labor costs for the worker are determined based on the sector, the reference location, the reference date, and the labor group.
    Number of Workers 2

  6. Enter some more values for other process parameters, tools and fixtures.

    Other Process Parameters
    Slider Type Mechanical Slider
    Insertion Parts Necessary
    Part Removal Type

    Robot Unload

    A further property for selecting the robot unloading type.
    Unload Robot Unload Robot Industrial robot | Payload: 6.00 kg | Reach: < 1,820.00 mm
    Tools and Fixtures
    Tool Cost 25,000.00 EUR
    % Tool Maintenance 2 %/a
    Fixture Cost 2,500.00 EUR
    % Fixture Maintenance 2 %/a
Note

Based on the selected material classification you can choose a material in the material selection. Accordingly, the following property values are determined via value rules:

  • Density
  • Available Clamping Force
  • Melt Temperature
  • Tool Temperature
  • Demolding Temperature
  • Defusion Rate

The properties are shown at the process in the Details view (Calculation view schema ) under Manufacturing Valuation > Miscellaneous Parameters > Component 1 > Material.

Step 4: Complete Structure

Based on your entries, the BOM structure of the cost model is being automatically created via the "Complete Structure" function.

Complete Structure of the Cost Model

  1. Select the process in the Structure view.
  2. Right-click > Complete Structure.

    3. Alternative: F11 in the Structure view or Details view.

    Based in your selection, a structure is automatically completed.

Note

Further changes are not applied immediately.

Perform the "Complete Structure" action again to update your cost model.