There are many factors that could influence your decisions when buying plastic toy products – the reasonable prices, its unique casing or attractive appearance, perhaps. However, do you know which department has the responsibility of the production the plastic toy casing you see on your products? Do you know which materials are used to achieve this? And, more importantly, do you know what's the reasoning surrounding this particular production process?
If the answer is no, don’t fret! In this article, we’ll tell you everything you need to know.
The casing of a plastic toy is mostly dependent on the toy model it will be used on. Injection molding is a common method used in the production of industrial products. You may have come across this process before. The section of a manufacturer that operates this is known as the injection molding department. They use machines and other pieces of high-tech equipment that can craft thermoplastics or thermosetting plastics into alternative products, for example, many of them being formed into different shapes. The molding machine will generate the plastic casing that you see on your toys. Large factories usually have large, medium and small injection molding machines, ensuring an increase in productivity and efficiency.
Plastic casing models of your toys generally use materials such as ABS, HIPS, GP, transparent ABS, PP, POM and PMmA. These materials are relatively hard and have a strong impact resistance, increasing their quality and also their popularity. Additionally, they are resistant to scratches, and own safety and environmental protection characteristics. A blend of these features created toys that are safe and certainly worth your money. Their durability is especially convenient if the toys are being used by children.
Most game consoles have casing that uses ABS plastic, and it’s a popular material in our industry.
Now that we’ve discussed the materials involved, it’s time to take a look at the production process.
Here’s what happens, step by step.
1.Firstly, the quality department offers hand-made samples confirmed by the customer2.Then, the engineering department offersthe production instruction worksheet3.The purchasing department orders the raw materials required4.The product is loaded into the machine, ready to be molded5.Following the international color number, adjust the colors as sample6.Ingredients are poured into the machine7.Melt and fix the model8.Take out the model after cooling9.Any leftover material from the molded product is cut off and removed10.IPQC inspect the quality of the products for 1-2 hours11.And, if inspection is passed, the products are put in the warehouse. If not, rework and repair happens.
You might have the misconception that a large injection molding machine will produce more toy models than that of a smaller one. Despite being logical reasoning, this would be incorrect. The production capacity is, in fact, determined by several factors. So, let’s talk about them.
1.THE PRODUCT REQUIREMENTS
If the casing is big and the process is harder, the speed will slow down, and the day production capacity will be less.
2.THE MOLD STRUCTURE
As large molds can only be produced in bigger machines, the production rate of complex molds will not be so high. And the bigger machine operation cost is also higher.
3.THE COOLING TIME
As previously mentioned, if the product is larger and therefore takes longer time to produce, it’ll take an increased amount of time to cool. This also affects the production quantity.
Additionally, product quality control takes place for 1 – 2 hours, in order to monitor the progress of the product’s molding. Once a signature is written to confirm everything is up to an acceptable standard, good quality can be guaranteed as the product passes into the next production process. Quality checking can prove to be especially beneficial, as poor quality can set the company back financial-wise.
After reading this article, we hope you have a more comprehensive understanding of the injection molding department and the roles they have to undertake. Don’t you think it’s an interesting and magical process? This department is an indispensable part of today’s industry, determining whether a product can be produced or not. Once you are more aware of what goes on behind the scenes, you’ll be able to have a more educated perspective whilst buying plastic toys. Not only will you know its operation performance, but you’ll get the reassurance that the products are danger-free and environmentally friendly.
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