From a single mould: precise injection moulds from Rejlek

The production of high-precision injection moulds of the highest quality is one of Rejlek’s most sought-after services. In this article, we take a closer look at how these moulds are used and the benefits they offer our customers.

The injection moulding process and its historical significance

The injection moulding process has been around since the late 19th century, when it was mainly used to make billiard balls and other everyday items from celluloid in order to save costs. The invention of the first screw injection moulding machine in 1946 significantly accelerated the process and improved efficiency, enabling the growing demand for low-cost consumer goods to be met.

Injection moulding has become one of the most important plastics processing techniques and is essential for many different industries – such as the automotive, mobility and electronics industries as well as medical technology. From mobile phone cases and toys to surgical devices and dashboards to insulators and device housings, an incredible quantity and variety of plastic items are produced in whole or in part using injection moulds. The fast, precise and cost-effective ability to produce plastic parts of any type and size has played a decisive role in shaping our modern everyday lives.

Design and function of injection moulding machines

But what do these devices look like that combine so much potential? A classic injection moulding machine consists of an injection unit and a clamping unit; the former heats and liquefies the raw material and then injects it under pressure into the moulding tool (or injection mould), which is located inside the clamping unit. The entire production process consists of four steps:

• Plasticising: The raw material is heated and liquefied
• Injection: The liquid material is filled into the injection mould under high pressure
• Cool down: The material is cooled in the mould and returns to its solid state
• Demoulding: The clamping unit is opened and the finished part can be removed

Injection moulds and injection mould construction

The injection mould, which determines the properties of the finished part, plays a particularly important role in this process. These permanent moulds are usually made of hardened steel or aluminium and consist of a nozzle side and an ejector side, which enclose the moulding die.

How simple or complex the injection mould is shaped depends on the job in question and can range from a conventional toy component to highly complex parts for machines. A single mould can also be used to produce several identical or different parts at the same time if this makes economic sense.

The development and production of high-quality injection moulds is the prerequisite for successful injection moulding production. Once this step has been completed and the finished mould is ready for use, thousands – or even hundreds of millions – of parts can be produced quickly, cost-effectively and with high precision, depending on requirements.

Injection mould construction at Rejlek

At Rejlek, the planning and production of injection moulds is one of our most important and sought-after areas of expertise. For many decades, we have been designing and manufacturing moulds according to customer requirements in our highly automated toolmaking facility in Vienna. From the initial idea to the end product and commissioning, we support our customers in this complex undertaking and ensure that we develop the best individual injection mould for them in the highest quality, enabling them to achieve their goals quickly and economically.

Our specialisation ranges from micro injection moulds with a part weight of 0.01 grams to mould sizes for injection moulding machines with a clamping force of 1100 tonnes. Our portfolio also includes moulds that are used for multi-component injection moulding – i.e. the combination of two or more plastics. Our products are able to meet very small tolerances and we ensure that the moulds produce only minimal scattering between the mould images.

In addition to our extensive experience, which we incorporate into every product, our in-depth understanding of metal and plastic in combination is also a significant advantage for our clients: We take responsibility for harmonising the two technologies, which significantly reduces the burden on our customers.

For each individual enquiry, a detailed feasibility study is prepared in advance and potential problem areas and optimisations are jointly agreed. As early as this development phase, we offer our customers optimum industrialisation by means of Design for Manufacturing (DFM) studies.

Conclusion: Get in shape with Rejlek

It is not without reason that injection mould construction is one of our masterpieces, for which we are widely known. Numerous customers from the medical technology, automotive and electronics industries rely on our expertise in this field and entrust us with their most challenging projects. Our team turns even the most complex orders into reality with heart and mind.

Would you also like to get into shape with us and develop injection moulds according to your individual requirements? Contact us – we look forward to receiving your enquiry and working with you.