Injection Moulding Polycarbonate (PC)
Material Description
Polycarbonate (PC) is a versatile and widely used engineering thermoplastic known for its exceptional combination of material properties. It is a transparent and amorphous polymer, characterized by its high impact strength, which is about 250 times greater than that of glass, making it ideal for applications requiring shatterproof materials. PC also exhibits excellent heat resistance, with a glass transition temperature of approximately 150°C, enabling its use in high-temperature environments without deformation. Additionally, it boasts good electrical insulating properties, further expanding its application range. Furthermore, PC demonstrates impressive optical clarity, making it a preferred choice for applications like eyewear lenses and optical discs. Its exceptional dimensional stability and resistance to UV radiation, as well as its ability to withstand various chemicals, including many oils and greases, make it suitable for outdoor and automotive components. Polycarbonate’s ease of processing through injection molding, extrusion, and thermoforming, coupled with its high impact strength, makes it an attractive choice for a wide array of industries, from consumer goods to aerospace, where a balance of mechanical, thermal, and optical properties is essential.
| Density (g/cm³) | Tensile Yield Strength (MPa) | Young's Modulus (MPa) | Melting Point (°C) | Thermal Conductivity (W/m-K) | Specific Heat Capacity (J/g·K) | Coefficient of Thermal Expansion (x 10^-6 /°C) | Water Absorption (%) |
|---|---|---|---|---|---|---|---|
| 1200 - 1230 | 60 - 80 | 2.2 - 2.4 | 150-155 | 0.20 - 0.34 | 1.2 - 1.4 | 65 - 70 | 0.2 - 0.4 |
Design Recommendation
When designing for injection molding with Polycarbonate (PC) material, it is crucial to consider several key factors to ensure optimal results. First and foremost, maintaining uniform wall thickness throughout the part is essential to prevent warping and sink marks. Additionally, incorporating generous fillets and radii in corners and edges helps distribute stress and reduces the risk of cracking. PC has a high melting temperature, so the mold should have efficient cooling channels to facilitate rapid and consistent cooling, preventing deformation and ensuring dimensional accuracy. Proper venting in the mold is important to prevent air traps and voids. Lastly, considering the draft angles for easy part ejection and texture on the mold surfaces to enhance the appearance of the final product can contribute to a successful PC injection molding process.
Cost Saving Tip
Cost-saving in Polycarbonate (PC) injection molding can be achieved through several key strategies. Firstly, optimizing the design and tooling of the injection mold is essential. This includes reducing unnecessary undercuts, simplifying part geometry, and ensuring proper gate and runner designs to minimize material waste and cycle times. Secondly, selecting the right PC resin is crucial, as choosing a grade with a balance of performance properties that meets the specific application requirements can reduce the need for post-processing or reinforcement, ultimately saving on material costs. Additionally, efficient processing parameters, such as barrel temperature, injection speed, and cooling time, should be fine-tuned to minimize energy consumption and cycle times. Implementing a comprehensive recycling program for scrap or rejected parts can further cut down on material costs and reduce environmental impact. Finally, embracing automation and monitoring systems can enhance overall process efficiency and reduce labor costs while maintaining consistent product quality. Employing these strategies can lead to significant cost savings in PC injection molding processes.
