Views: 0 Author: Site Editor Publish Time: 2025-04-18 Origin: Site
Partial Plastic Injection
70-95% of molten plastic (e.g., PP, PC/ABS) fills the mold.
Gas Injection
High-pressure nitrogen (50-300 bar) is injected through nozzles.
Gas Penetration
The gas pushes plastic into remaining cavities, forming hollow channels.
Cooling & Ejection
Gas maintains pressure to prevent sink marks → final part ejection.
Key Advantage: Up to 40% material savings vs. solid parts.
| Parameter | Gas-Assisted Injection Molding | Conventional Molding |
|---|---|---|
| Wall Thickness | Variable (3-15mm) | Uniform (typically 2-4mm) |
| Sink Marks | Virtually eliminated | Common in thick sections |
| Cycle Time | 20-35% faster | Standard |
| Tooling Cost | 15-30% higher | Lower |
| Part Weight | 15-40% lighter | No reduction |
✅ Eliminates Sink Marks – Perfect for large flat surfaces (e.g., TV bezels).
✅ Lightweighting – Automotive parts can be 30% lighter (e.g., door handles).
✅ Lower Internal Stress – Gas pressure distributes evenly, reducing warpage.
✅ Design Freedom – Integrates ribs, tubes, and complex geometries in one shot.
✅ Cost Efficiency – Saves material and reduces post-processing.
Intake manifolds (replaces metal, 40% weight savings)
Door handles (Class-A surface finish)
Dashboard supports (structural + lightweight)
TV/display frames (Samsung, LG widely adopt GAIM)
Laptop hinges (hollow-core strength)
Washing machine drums
Air conditioner vents
Chair armrests
Shower frames
Shape: Circular > Oval > Rectangular
Size: Minimum 3x wall thickness
Layout: Follow primary load paths
Best Choices: PC/ABS, PP, glass-filled nylon
Avoid: Clear plastics (optical defects), high-viscosity resins
| Parameter | Optimal Range | Impact |
|---|---|---|
| Gas Pressure | 50-300 bar | Determines channel quality |
| Delay Time | 0.5-3 seconds | Affects plastic flow front |
| Gas Hold Time | 20-40% of cycle | Prevents shrinkage |
⚠ Blow-Through
Cause: Too much gas pressure / insufficient plastic
Fix: Increase shot size by 5-10%
⚠ Finger Effect
Symptom: Wavy lines near gas channels
Solution: Adjust gate location / reduce gas pressure
⚠ Uneven Gas Penetration
Fix: Use multi-point gas injection
Water-Gas Hybrid Molding
Combines gas and water for ultra-thin walls (used in BMW bumpers).
Smart Gas Control
AI-driven real-time pressure adjustment (±0.5 bar precision).
Supercritical Fluid (SCF) Assisted GAIM
Uses supercritical CO₂ for smoother surfaces.
✔ High-volume production (>100k parts/year)
✔ Weight-sensitive applications
✔ Large parts requiring structural integrity
Higher initial tooling cost (ROI in 8-15 months)
Requires specialized mold design
Pro Tip: Run CAE gas-flow simulations before tooling.
GAIM revolutionizes plastic part manufacturing by delivering lighter, stronger, and more cost-effective components. From automotive to consumer goods, its ability to eliminate defects while enabling innovative designs makes it a top choice for engineers.
