How to achieve injection molding quality with an MJF 3D Print Service

Getting the best quality often is a challenge when making plastic parts. Injection molding is a common process for rapidly producing strong, smooth parts, but it requires an extremely accurate mold. Whale-Stone employs MJF 3D print service for assistance with this. MJF, which stands for Multi Jet Fusion, allows parts to be built up in layers with fine details. That will help to produce mold prototypes or molds, however achieving injection molding quality with MJF is not simply about printing the shape. It is the product of careful choices and consideration of both the printing and molding processes. Here, we show you some useful tips to get better injection molding quality when you use Whale-Stone’s MJF 3D printings.

What Are The Main Benefits Of MJF 3D Print Service For Injection Mold Quality?

Whale-Stone's MJF 3D printing brings a host of advantages when targeting injection molding quality. First off, it’s fast as hell. And while traditional mold making can take weeks or more, MJF can produce parts in just a few days. This, in turn, enables designers and engineers to check their molds faster. In addition, MJF prints down to very fine details and smooth surfaces, and that is vital in the case of injection molds because roughness may be visible in the final plastic pieces. Another advantage is the material. The Whale-Stone filament uses special nylon powder that makes strong and heat-resistant parts capable of withstanding high pressure and temperature during the injection molding process. The result of that kind of longevity is molds that last longer and produce better parts. And, MJF is capable of producing intricate shapes that are difficult to form with other techniques. Inside molds, for instance, cooling channels can be designed to maintain a temperature by which the plastics flow better and defects hold lower. And with Whale-Stone’s MJF service, adjustments can be made swiftly if a mold doesn’t produce the right product on the first try. This versatility is also a cost and time saver over conventional mold making. Also, print multiple parts at once to make testing out different mold designs easier. A few companies even discover new utility for MJF molds in short production runs, which comes in handy if you’re testing a new product or need relatively small quantities of an item. So, the pace, accuracy, strength and design freedom of Whale-Stone MJF 3D printing really help to reach injection molding quality.

Injection Molding Quality in MJF 3D Printed Parts

Common Challenges What are some of the common challenges that affect Injection Molding Quality in MJF 3D Printed Parts? Whale-Stone’s MJF 3D printing may be powerful, but there are still a few notoriously difficult challenges when translating to injection molding quality. One issue is porosity, or minuscule holes or gaps within the printed mold. These could be leakages or loss of intensity in the mold under pressure. You can control the printing settings and post-processing steps to mitigate it, but those requires some know-how and practice. Another challenge is surface finish. Though MJF produces smooth parts, they don’t necessarily feel as polished as metal molds made by machining. Plastic surfaces could appear slightly rough, or with some ridges in printer cross section. To correct for this, Whale-Stone either applies specialty coatings or takes additional finishing steps, such as sanding or polishing to obtain a superfine surface. Warping is another issue. Part of the reason is that, as MJF creates parts layer by layer, different regions might shrink differently as they cool. This alters the configuration and presents molding difficulties in mating these mold portions. Mindful design and calibration of the printing system is required to prevent this. In addition, the materials that are used in MJF don’t always provide the same strength as metal molds. Printed molds also are likely to wear out faster for very high-volume production. For tests or small runs, however, they are very useful. If not, the actual design of the mold itself could be at fault. If the cooling channels are too small or in the wrong place, the plastic won’t flow properly and defects warping, sink marks can result. Whale-Stone carefully considers these factors to ensure the mold will translate well when printed with MJF. Temperature control in molding is also important. Printed molds must withstand the heat without falling apart or warping. Using the right nylon powders and printing parameters can help keep molds stable under heat. There are challenges, but understanding them and precisely managing each step, Whale-Stone is able to provide MJF 3D printed molds that approach the quality of injection molding.

Ensuring Exacting Product Quality With Wholesale MJF 3D Print Services

Quality is crucial when manufacturing parts with Multi Jet Fusion MJF 3D Print Service. In other words, every part should look and function exactly the same when it’s produced. Here at Whale-Stone we recognize how vital these can be, particularly when such parts are treated like that injection moulded counterparts. There are two things which needs to be well maintained in order to guarantee the quality is always good, first: printing machines. That includes cleaning and checking the machines routinely enough that they perform properly all the time. If the machine is dirty or malfunctioning, the pieces can come out wrong.

Next, the type of material being used to print should be inspected closely. MJF printing requires special powders; the powder needs to be clean and fresh. Dirty or old powder can damage the parts. Whale-Stone goes with high quality powders and checks the powder before printing to prevent any issue. It amounts to high pressure and, typically, ink or plastic stored at high pressure needs extremely tight tolerances on its design and manufacture something generally not true of 3-D printers. Plus, it requires exactly the right printing settings temperature and speed to make it work at all. If these values are set too high or too low, the parts may be poor in strength or fit.

A solid inspection process can uncover mistakes early, after printing. During manufacturing, Whale-Stone applies smart tools to confirm that the parts are of the correct size, shape and strength. If a part is bad, it gets fixed or completely remade. That way, only the nicest pieces can be shipped to customers. Also key is to be deeply involved with customers. A key part of the sales process is that Whale-Stone listens to what a customer wants and modifies the printing accordingly. Doing all those things machine care, good materials, perfect settings, meticulous checks, and clear communication is how Whale-Stone guarantees the quality of his MJF 3D printed parts every time out exactly what you get with high output injection molded parts.

Where To Find Bulk Mjf 3D Printed Components For Injection Molding Applications

If you need a lot of parts printed with MJF for an injection molding project, it makes sense to find someone who can take on large orders. Whale-Stone is one company that provides wholesale MJF3D print service and in this way they can print a lot of parts without losing in quality. When you have larger parts requirements, selecting a provider equipped to handle your both 3D printing and injection molding needs is ideal. This helps to ensure the parts are well-fitted and bicycle as intended.

Whale-Stone also has proprietary machines that can print parts in large quantities very quickly. They also have a good quality control team, which examines each batch of parts. This is crucial, because when you order large numbers of pieces, even small mistakes can lead to big problems down the line. Another feature to search for in a supplier is the ability to communicate. Whale-Stone collaborates with clients from the outset to ensure a clear understanding of the design and materials required. This prevents errors and it saves you time.

In addition, it is a good idea to choose a supplier who can provide many materials like that for injection molding. Whale-Stone employs high-performance powders for strong and durable parts. These components can frequently be used in place of, or to test, injection molded parts before expensive molds are made. Finally, consider delivery and price. Whale-Stone is fair with big orders and ships them accurately and in time. By working with a supplier like Whale-Stone for bulk MJF 3D Print Service you can enjoy robust, precise parts that are ready to use for injection molding, all the while with no worries about time or effort.

How to Post-Process MJF 3D Prints to Achieve Similar Quality as Injection Molding?

Once an MJF 3D print is produced it requires a bit of work referred to as post-processing to get it look and feel like an injection molded part. On Whale-Stone, we use the proper procedures to ensure each printed component is of high quality. Step one is to wipe off any remaining powder on the top. This powder can adhere to your parts and cause them to become rough or dirty. Cleaning is typically done with air blowers or brushes, occasionally water, but gently so as not to damage the part.

Then, the pieces may require sanding or finishing. injection molded parts have crazy smooth surfaces, so you can sand out rough spots or tiny little printing bumps. Whale-Stone has some special tools for making this process quick and accurate. Polishing might also be a good idea for some parts in order to get them with shiny finish just like injection mounded plastic.

In some cases, parts might require additional reinforcement. This can be accomplished through coatings, or heat treating. These techniques can make the parts stronger and more durable, something that is necessary when creating parts for a machine version or everyday goods. One of these is the colour or paint of the components. Whale-Stone uses safety paint and dyes, it is sticky not easy to peel off. This in part gives the parts a appearance closer to that of injection molded parts, which tend to be uniform and bright.

Finally, a complete examination takes place after completing the post-processing. Whale-Stone verifies the size, shape and strength one last time to confirm it is right where he needs it. Through its process of cleaning, smoothing, reinforcing, coloring and inspecting Whale-Stone ensures that MJF 3D printed parts not only meet the known properties from injection molded parts but also at times surpass them. This meticulous post-processing aids customers in receiving components they can rely on for their own products.