Fusible core injection molding

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Fusible core injection molding, also known as lost core injection molding, is a specialized
plastic injection molding process used to mold internal cavities or undercuts that are not possible
to mold with demoldable cores. Strictly speaking the term "fusible core injection molding refers
to the use of a fusible alloy as the core material; when the core material is made from a soluble
plastic the process is known as soluble core injection molding. This process is often used for
automotive parts, such as intake manifolds and brake housings, however it is also used for
aerospace parts, plumbing parts, bicycle wheels, and footwear.[1][2]
The most common molding materials are glass-filled nylon 6 and nylon 66. Other materials
include unfilled nylons, polyphenylene sulfide, glass-filled polyaryletherketone (PAEK), glass-
filled polypropylene (PP), rigid thermoplastic urethane, and elastomeric thermoplastic
polyurethane.[3][4]

Contents
[hide]
• 1 History
• 2 Process
○ 2.1 Core
○ 2.2 Molding
○ 2.3 Melt-out
○ 2.4 Equipment
• 3 Advantages and disadvantages
• 4 Application
• 5 References
○ 5.1 Bibliography
• 6 External links

[edit] History
The first patent for this type of molding process was taken out in 1968, however it was rarely
used until the 1980s. That is when the automotive industry took interest in it to develop intake
manifolds.[5][6]
[edit] Process
The process consists of three major steps: casting or molding a core, inserting the core into the
mold and shooting the mold, and finally removing the molding and melting out the core.
[edit] Core
First, a core is molded or die cast in the shape of the cavity specified for the molded component.
It can be made from a low melting point metal, such as a tin-bismuth alloy, or a polymer, such as
a soluble acrylate. The polymer has approximately the same melting temperature as the alloy,
275 °F (135 °C), however the alloy ratios can be modified to tweak the melting point. Another
advantage to using a metal core is that multiple smaller cores can be cast with mating plugs and
holes so they can be assembled into a final large core.[7][8]
One key in casting metal cores is to make sure they do not contain any porosity as it will induce
flaws into the molded part. In order to minimize porosity the metal may be gravity cast or the
molding cavity may be pressurized. Another system slowly rocks the casting dies as the molding
cavity fills to "shake" the air bubbles out.[9]
The metal cores can be made from a number of low melting point alloys, with the most common
being a mixture of 58% bismuth and 42% tin, which is used for molding nylon 66. One of the
main reasons its used is because it expands as it cools which packs the mold well. Other alloys
include tin-lead-silver alloys and tin-lead-antimony alloys. Between these three alloy groups a
melting point between 98 and 800 °F (37–425 °C) can be achieved.[3]
Polymer cores are not as common as metal cores and are usually only used for moldings that
require simple internal surface details. They are usually 0.125 to 0.25 in (3.2 to 6.3 mm) thick
hollow cross-sections that are molded in two halves and are ultrasonically welded together. Their
greatest advantage is that they can be molded in traditional injection molding machines that the
company already has instead of investing into new die casting equipment and learning how to
use it. Because of this polymer core materials are most adventitious for small production runs
that cannot justify the added expense of metal cores. Unfortunately it is not as recyclable as the
metal alloys used in cores, because 10% new material must be added with the recycled material.
[10][11]

[edit] Molding
In the second step, the core is then inserted into the mold. For simple molds this is as simple as
inserting the core and closing the dies. However, more complex tools require multiple steps from
the programmed robot. For instance, some complex tools can have multiple conventional side
pulls that mate with the core to add rigidity to the core and reduce the core mass. After the core
is loaded and the press closed the plastic is shot.[8]
[edit] Melt-out
In the final step, the molded component and core are both demolded and the core is melted-out
from the molding. This is done in a hot bath, via induction heating, or through a combination of
the two. Hot baths usually use a tub filled with glycol or Lutron, which is a phenol-based liquid.
The bath temperature is slightly higher than that of the core alloy’s melting point, but not so high
that it damages the molding. In typical commercial applications the parts are dipped into the hot
bath via an overhead conveyor. The advantage to using a hot bath is that it is simpler than
induction heating and it helps cure thermoset moldings. The disadvantage is that it is
uneconomically slow at a cycle time of 60 to 90 minutes and it poses environmental cleanup
issues. Typically a the hot bath solution needs cleaning or replacement every year or every half
year when used in combination with induction heating.[10]
For thermoplastic moldings induction heating of the core metal is required, otherwise the
prolonged heat from a hot bath can warp it. Induction heating reduces the melt-out time to one to
three minutes. The disadvantage is that induction heating does not remove all of the core material
so it must then be finished off in a hot bath or be brushed out. Another disadvantage is that the
induction coils must be custom built for each molding because the coils must be 1 to 4 in (25 to
100 mm) from the part. Finally, induction heating systems cannot be used with moldings that
have brass or steel inserts because the induction heating process can destroy or oxide the insert.
[12]

For complex parts it can be difficult to get all of the core liquid to drain out in either melt-out
process. In order to overcome this the parts may be rotated for up to an hour. Liquid core metal
collects on the bottom of the heated bath and is usable for a new core.[12]
[edit] Equipment
Traditional horizontal injection molding machines have been used since the mid-1980s, however
loading and unloading 100 to 200 lb (45 to 91 kg) cores are difficult so two robots are required.
Moreover, the cycle time is quite long, approximately 28 seconds. These problem are overcome
by using rotary or shuttle action injection molding machines. These types of machines only
require one robot to load and unload cores and has a 30% shorter cycle time. However, these
types of machines cost approximately 35% more than horizontal machines, require more space,
and require two bottom molds (because one is in the machine during the cycle and the other is
being unloaded and loaded with a new core), which adds approximately 40% to the tooling cost.
For small parts horizontal injection molding machines are still used, because the core does not
weight enough to justify the use of a rotary machine.[13]
For four-cylinder manifolds a 500 ton press is required; for a six- to eight-cylinder manifold a
600 to 800 ton press is required.[13]
[edit] Advantages and disadvantages
The greatest advantage of this process is its ability to produce single-piece injection moldings
with highly complex interior geometries without secondary operations. Similarly shaped objects
are usually made from aluminium castings, which can weight 45% to 75% more than a
comparable molding. The tooling also lasts longer than metal casting tooling due to the lack of
chemical corrosion and wear. Other advantages include:[4]
• Very good surface quality with no weak areas due to joints or welds
• High dimensional accuracy and structural integrity
• Not labor intensive due to the few secondary operations required
• Little waste
• Inserts can be incorporated
Two of the major disadvantages of this process are the high cost and long development time. An
automotive part can take four years to develop; two years in the prototype stage and two years to
reach production. Not all products take this long, for instance a two-way valve produced by
Johnson Controls only took 18 months. The initial cost can be as much as $8 million USD to
produce a four cylinder engine manifold. However, computer flow analysis has helped reduce
lead time and costs.[1][14]
One of the difficulties that result in these long development times and high costs is in making
accurate cores repeatably. This is extremely important because the core is an integral part of the
mold, so essentially each shot is into a new mold cavity. Another difficulty is keeping the core
from melting when the plastic is shot into the mold, because the plastic is approximately twice
the melting temperature of the core material. A third difficulty is the low strength of the core.
Hollow plastic cores can collapse if too much pressure is used in the shot plastic. Metal cores are
solid so they cannot collapse, but are only 10% as strong as steel cores so they can distort. This is
especially a problem when molding manifolds, because the waviness of the core can be
detrimental to the airflow within the runners.[7]
Another disadvantage is the need for a large space to house the injection molding machines,
casting machines, the melt-out equipment, and robots.[4]
Because of these disadvantages some moldings that would be made via this process are instead
made by injection molding two or more parts in a traditional injection molding machine and then
vibration welding them together. This process is less expensive and requires much less capital,
however it imparts more design constraints. Because of the design constraints sometimes parts
are made with both processes to gain the advantages of both.[15]
[edit] Application
The application of the fusible core process is not limited just to the injection of thermoplastics,
but with corresponding core alloys also to thermosetting plastic molding materials (duroplast).
The fusible core process finds application, for example, for injection molded passenger car
engine intake manifolds. By modifying the equipment, small molded parts like valves or pump
housings can be manufactured, as the manufacture of the fusible cores and the injected parts can
be carried out on an injection molding machine.