PC Injection Molding
Services On Aria
Polycarbonate (PC) is a natural transparent engineering plastic and one of the most common injection molding materials. This material has a low shrinkage base for injection molded parts.
Upload 3D CAD File to Start A New Injection Molding Quote
What is Polycarbonates Plastic?
Among numerous thermoplastics suitable for injection molding, polycarbonate stands out. When optical clarity and toughness are essential, it becomes the top choice. Besides injection molding, polycarbonate can also be processed through extrusion, blow molding, and thermoforming techniques.
Description
Full Name
Polycarbonates
Process
Finishing options
Mold texturing，Pad printing，Laser engraving，Electroplating, Bead Blasting
Appearance
Black / Transparent
Prices
$
Features
Density
1.20 g/cm3
Strengths
High impact strength, Lightweight, Heat resistance, Heat resistance
Tensile Strength
9500 PSI
Elongation at Break
6.10 – 138%
Hardness
Rockwell R hardness of 114 – 124
Advantages of PC Injection Molding
There are many benefits derived from plastic molding, Some of the advantages of the material include:
Mechanical Properties
PC has high strength, toughness, and rigidity, enabling it to withstand impacts and stress without easily breaking or deforming.
Good Dimensional Stability
It maintains its shape well under different temperature and pressure conditions, with minimal warping or shrinkage.
High Temperature Resistance
PC can perform well in relatively high-temperature environments compared to many other plastics, with a melting point around 240 °C.
Good Electrical Insulation
PC provides good electrical insulating properties, making it suitable for use in various electrical and electronic applications.
Flame Retardant
Some grades of PC are naturally flame retardant, enhancing fire safety in applications like electrical equipment housings and building materials.
Disadvantages of PC Injection Molding
High Cost
PC has high strength, toughness, and rigidity, enabling it to withstand impacts and stress without easily breaking or deforming.
Difficult processing
Its high melt viscosity and poor fluidity make it hard for the molten material to fill the mold evenly, especially for complex or thin-walled products.
Easy to orrode
PC can be vulnerable to certain solvents and strong alkalis, requiring careful material selection for specific environments.
Poor wear resistance
The wear resistance of PC materials is relatively poor, and in applications where wear resistance is required, such as gears, bearings, etc.,
Prone to stress cracking
PC materials are prone to stress cracking, which seriously affects the reliability and service life of the product.
Applications of PC Injection Molding
PC Injection Molding Material Properties
PP Plastic Properties
Value
Tensile Strength (Yield) （MPa）
9000 - 9500
Flexural Modulus（GPa）
0.971 - 3.10
Impact Resistance (Izod Impact, Notched)
17 ft-lb/in
Maximum Service Temperature（℃）
90 -140
Chemical Formula
(C16H14O3)n
Glass Transition Temperature（℃）
147
Heat Deflection Temperature（℃）
130
Drying Temperature（℃）
110 -120
Drying Time（hr）
2 - 4
Mold Temperature（℃）
50～90
Melt Temperature（℃）
260～290
Injection Pressure（MPa）
90～140
Injection Speed（ mm/sec）
High
Cooling Time（S）
20～60
Scrap Quantity（mm）
3～8
Back Pressure（MPa）
2～6
Clamping Force（ton/in2）
4～８
Return Speed (rpm)
70～90
Shrinkage
0.6%
PC Injection Molding Design Guide
Wall Thickness
Generally, the minimum recommended wall thickness stands at around 0.040 inches (equivalent to 1 mm), which allows for the creation of delicate and space-efficient designs. Meanwhile, the maximum advisable wall thickness is capped at 0.150 inches (or 3.8 mm)
Ribs
The thickness of ribs should be about 60 – 80% of the adjacent wall thickness to avoid sink marks on the outer surface.
Draft Angle
For PC injection molding, a minimum draft angle of 0.5° – 1° is recommended for external surfaces, and 1° – 2° for internal surfaces.
Corners and Fillets
Sharp corners should be avoided as they act as stress concentrators. Replace sharp corners with fillets, with a radius typically between 0.030 – 0.120 inches (0.75 – 3 mm), depending on the part size and application. Fillets help distribute stress evenly and improve the overall strength of the part.
Holes
Holes in PC parts should have a diameter larger than the thickness of the material to prevent cracking during molding. If possible, use through-holes rather than blind holes to simplify the mold design and material flow.
Gate Location
Runner System
Custom parts for your aerospace projects now
All information and uploads are secure and confidential.
Related Post
What is melt index for injection molding?
Melt index is a number that indicates the fluidity of plastic materials during processing. It is the American Measurement Standards Institute (ASTM), according to the
The tensile strength of injection molding plastic
The injection molding process is a process involving mold design, mold manufacturing, raw material characteristics, and raw material pretreatment method, molding process, injection molding machine operation, and
Physical and mechanical properties of injection molded plastic
We use plastic almost every day, and many people use plastic to design products, but few of them have a thorough understanding of the characteristics