Revolutionising Injection Moulding Tool Maintenance: The Superiority of Laser Cleaning

Introduction:

Injection moulding is a widely used manufacturing process that produces high-quality, complex plastic components. To ensure the efficiency and longevity of injection moulding tools, regular maintenance is essential. Traditional cleaning methods, such as abrasive techniques (soda blasting, dry ice blasting, manual scrubbing) and chemical solvents, have been the traditional method for years. However, there's a more modern and more effective cleaning technology that has started to gain popularity: Laser Cleaning. In this post, we'll explore why laser cleaning has emerged as the superior choice for maintaining injection moulding tools over traditional methods and the benefits it brings to manufacturers.

How does it work:

The process by which Lasers remove surface contaminants is called 'Laser Ablation', you can read more about this on our page here. The process involves the unwanted contaminant absorbing the laser energy, this creates a thermal shock on the contaminant resulting in it being evaporated or turned into a plasma, depending on the laser power and parameters.

5 Benefits for using Lasers to clean tools and machinery:

1. Precision and selective control:

Laser cleaning is a non-contact method that relies on the precision of laser beams to remove contaminants from surfaces. These lasers utilise specific parameters such as pulse width, pulse frequency and power output which allow them to precisely remove just the right amount of contaminant, without scratching or harming the base surface. This is an ideal solution for cleaning injection moulding tools as lasers can be used to clean intricate areas such as key holes on platern's, screws and O-ring recesses, something that can is commonly a laborious task for a team of tool maintenance engineers when done by hand. This precision is crucial for maintaining the dimensional accuracy of injection moulding tools and ensuring the quality of the moulded products. This also has the added benefit of extending the tools lifespan by keeping the material within specification for longer, thanks to the non-abrasive action of lasers.

2. Time and Cost Efficiency:

Time is money in the manufacturing industry; some machines we've seen can produce 48 pieces every 8 seconds, add this up over a week long shutdown and you can see the loss in production that occurs during service cycles. Compared to blasting and other traditional methods, Lasers are a far more efficient method at cleaning moulding tools as they have far more control in their application, such as the use of large and small beam widths which can be altered according to the shape and size of the area being worked on. Furthermore laser cleaning machines have adjustable power parameters and settings allowing them to remove thick and thin contaminant layers at an incredibly fast rate.

Laser Cleaning machines require little setup space and can be mobile enough to work around most workshops, providing the correct safety procedures are followed as laser safety screens are required to separate the workspace from potential on-lookers.

This efficiency in operation translates into reduced downtime for injection moulding machines, ultimately saving on production costs and increasing overall operational efficiency.

3. Environmentally Friendly:

Traditional cleaning methods often involve the use of abrasive materials and harsh chemicals, which can pose environmental and health risks. Laser cleaning, on the other hand, is a green and sustainable solution. It eliminates the need for chemical solvents and reduces the generation of hazardous waste. This eco-friendly approach aligns with the growing demand for sustainable manufacturing practices and compliance with environmental regulations.

4. No Secondary Waste:

Abrasive cleaning methods can generate secondary waste, such as spent blast media and contaminated cleaning agents. This not only adds to the disposal costs but also poses challenges in waste management. Laser cleaning, being a non-abrasive and non-chemical process, produces minimal to no secondary waste. Any airborne particles that may be produced through laser ablation are extracted through an advanced filtration system (often using HEPA filters) which means there are no harmful fumes or airborne particles left behind. This not only streamlines the cleaning process but also contributes to a cleaner and more efficient manufacturing environment. This is a far easier setup than blasting methods such as sand or soda blasting as these methods require an isolated workspace or often full transportation of parts to an external site in order to contain and isolate the blast media, further adding to extended shutdown times and cost.

5. Safety and Operator Health:

The use of abrasive materials and chemical solvents in traditional cleaning methods can expose operators to safety hazards and health risks. In contrast, laser cleaning minimises these risks. It eliminates the need for operators to handle abrasive materials or come into direct contact with potentially harmful chemicals. Whilst safety protocols are certainly required when operation a laser cleaning (safety goggles, respirators, safety screens) the risk to operators is vastly reduced when these protocols are met as the precise application of a laser beam is far easier to manage and control than blast media and chemical methods.

Conclusion:

As the manufacturing industry continues to evolve, embracing innovative technologies becomes imperative for staying competitive. Laser cleaning has emerged as a game-changer in the maintenance of injection moulding tools, offering precision, environmental friendliness, safety, and cost efficiency. By transitioning from traditional methods to laser cleaning, manufacturers can not only enhance the lifespan of their injection moulding tools but also contribute to a more sustainable and efficient production process. It's time for the industry to embrace the laser revolution and redefine the way we approach tool maintenance in injection moulding.