From the specialized porcelain labware first made in 1915, to modern electronic devices, CoorsTek uses advanced technology, materials, manufacturing, and assembly to remove technological barriers for design engineers worldwide.
Ideal for high-volume production of complex, tight-tolerance components, injection molding offers significant advantages over conventional forming methods:
· Cost-effective technique for complex designs
· Ability to produce net or near-net shape parts
· Very tight tolerance control
· Polymer insert molding over metal, ceramic, and plastic
· Low-cost, high-volume manufacturing runs
· High-strength properties – up to 30% gain over conventional
· Variety of advanced materials available to meet numerous application needs
Injection Molding Process
Our experts help you choose from a multitude of advanced materials including technical ceramics, high-performance plastics, and advanced metals.
State-of-the-art injection molding machines heat feedstock to a flowable state and pressure inject it into a steel mold. The part then is cooled until solid and ejected from the mold.
Some materials may require either thermal or chemical bath debinding prior to the sintering process.
In kilns capable of exceeding 1600°C, ceramics and metals are sintered to full density, removing any remaining binders or organics.
Advanced plastics are annealed for optimum properties and low stresses.
If needed, operations such as tumbling, polishing, or machining are available to meet customer specifications.
In-Process and Final Inspection
Throughout the manufacturing process, quality controls ensure components meet customer requirements. CoorsTek offers on-line Statistical Process Control and is ISO-9002 certified.
Process intended for components with complex geometries or large-volume runs. CoorsTek engineers offer component design assistance to maximize the advantages of the injection molding process.
Injection molding can produce complex shapes that would normally require secondary operations. Generally the more complex the geometry, the more advantageous injection molding will be over other fabrication methods. Following are some general guidelines:
· Thin, uniform cross sections are best
· External tapers and undercuts are permissible; internal contours and undercuts are feasible
· Flat surfaces are ideal for support during sintering of ceramics. However, when design does not permit, special saggers can be molded with the part to add extra support
Extremely Tight Tolerances (up to ± 0.05%)
CoorsTek design engineers help determine appropriate tolerances.
Draft angles, ejector pin marks, parting lines, gate marks, flow lines, and mismatches are some of the features that may be evident on parts. CoorsTek engineers will work with you to minimize the effect of these features on the functionality of the part.
· AD-998 (Nom. 99.8% Al2O3)
· AD-995 (Nom. 99.5% Al2O3)
· FG-995 (Nom. 98.5% Al2O3)
· AD-95 (Nom. 95% Al2O3)
· AD-94 (Nom. 94% Al2O3)
· YTZP (Y2O3 Partially Stabilized Zirconia)
· TTZ (MgO Partially Stabilized Zirconia)
· ZTA (Toughened Alumina ZTA)
· WCNi (Tungsten Carbide Nickel)
· WCCo (Tungsten Carbide Cobalt)
· SiC (Silicon Carbide)
· Porous Materials
· ESD-Safe Materials
High Temperature Polymers
· Polyimide (TPI)
· Polyetherimide (PEI)
· Polyethersulfone (PES)
· Liquid crystal polymer (LCP)
· Stainless Steel