Injection Mold

Material is introduced into the injection molding machine via a Hopper.  The injection moulding machine consists of a heated barrel equipped with a reciprocating screw (driven by a hydraulic or electric motor), which feeds the molten polymer into a temperature controlled split mould via a channel system of gates and runners.  The screw melts (plasticises) the polymer, and also acts as a ram during the injection phase. The screw action also provides additional heating by virtue of the shearing action on the polymer. The polymer is injected into a mould tool that defines the shape of the moulded part.  The pressure of injection is high, dependant on the material being processed; it can be up to one thousand atmospheres.  Tools tend to be manufactured from steels, (which can be hardened and plated), and Aluminium alloys for increased cutting and hand polishing speeds.  The costs associated with tool manufacture means that injection moulding tends to lend itself to high volume manufacture.  Details of process costing can be found at:

The tool can be used to manufacture one consistent part in a repeating process or incorporate multi cavities (a multi impression tool), that is many components can be manufactured on the same tool repeatedly with a single injection. 

It should be noted that, whilst in the animation the flute pitch of the screw is shown as constant along its length, in practice it varies considerably dependent upon the polymer being processed. In particular the root diameter increases from hopper to nozzle to provide compression to the melt.

Source: http://www.bpf.co.uk/plastipedia/processes/injection_moulding.aspx

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