Case Study | Bosch

AV injection purchased a Billion 1000 tonne Injection Moulding machine to be able to Injection mould a product for Bosch.
The Billion Injection Moulding machine that we use allows precise controls on injection speeds, pressure and temperatures, which are needed to produce detailed quality products.

AV Injection used a servo controlled robot to release the part from the mould and place onto a conveyor system. The servo motors give very accurate movements needed to remove this part from the mould tool. We then ensure that the component parts coming off the mould are well within the tolerance levels.
From this  position a three station rig was manufactured to hold the component in place. This rig had several locking toggle clamps that were set to very precise tolerances to keep the product flat.  After the original design was manufactured, a major modification was added to speed up the cycle time of the machine.
A series of cooling air fans were added below the three stations decreasing the cooling time so the product could be removed from the jig quicker, hence the cycle time improved dramatically. Sensors were fitted along with a programmable logic controller, programmed so only finished products could be released from the jig units.
If you would to discuss how we can help with your project please Contact Us.

AV Injection | Plastic Parts Assembly

Over the past 10 years we have established and trained a dedicated team of operators in our Plastic Parts Assembly department. Plastic parts are generally assembled at press side either by one of our fully automated robots or by trained and dedicated press side labour.

• 1) Product picking, placing into packages as part of an accessories kit, labeling and boxing into correct quantity.
• 2) Assembly of products using hand held Pistol Drills.
• 3) Use off Ultrasonic Welding equipment.
• 4) Wiring of electrical products.
• 5) Testing of product by means of test rigs to ensure wiring and assembly is correct and fit for function.

We are proud to have several decades of experience in Plastic Parts Assembly, and equally as proud to retain many of clients such as Bosch. We are certain that our technical parts assembly has played a major role in retaining and attracting new global customers.

Below is a short summary of some of the Plastic Assembly work currently undertaken for Bosch Lawn and Garden.

• 1) Handles for Lawn Mowers, This involves the assembly of Plastic Parts using drills and testing by means of electrical test machines to ensure product is fit for function.
• 2) Motor Cover assembly of parts and wire looms and testing by means of electrical test machine.
• 3) Felling handle assembly.
• 4) Wire assembly of throttle cables for lawn mowers and electrical testing.
• 5) Ultrasonic Welding of back plates to wheels for lawn mowers.

If you would like to discuss how we could help with your project please Contact Us.

Services | Injection Moulding

UK Injection Moulding Manufacturers

Based in the Midlands UK, AV Injection are the UK's leading Injection Moulding Manufacturers for a variety of industries. We are a leading Plastic Injection Moulding company with long established mould manufacturing relationships with many UK and International brands such as Aston Martin, Bosch and the BBC.

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• - Over 30 years injection moulding manufacturing and design experience.
• - Established partnerships with local design houses.
• - Injection Mould Prototyping including SLA, SLS, FDM, CNC & Silicone - lead time from 2 days.
• - Pre production/Prototype tooling manufactured in as little as 2 weeks.
• - Plastic Injection Moulding 3D modelling can be provided so the feel of the idea can be seen, touched and tested.
• - Use of various CAD systems and Mould Flow analysing software that can show how your part can be produced.
• - In house Tool room can produce prototype tooling in short lead times to produce a fully working model.

As premier UK Injection Moulding Manufacturers, AV Injection enjoy significant experience and knowledge of most raw materials ensuring that our injection moulding manufacturing design process avoids costly errors through using incorrect or unsuitable materials. If required we can offer a full trial operation for customers and UK Toolmakers allowing clear views, results and problem solving.

If you would like to discuss how AV Injection, premier UK Injection Moulding Manufacturers, could help with your injection moulding manufacturing project please Contact Us.

AV Injection | Hello From AV Injection

Introduction from AV Injection Limited View this email in your browser

Hello From AV Injection by Kevin Youens - Sales Manager AV Injection are a plastic injection moulder based in the Midlands, supplying mouldings from 33 machines up to 6kg in shot weight. Also offering additional services such as printing, welding, extrusion & assembly. We supply a vast range of industries from all over the UK & Europe. We are able to offer a complete package from support at the earliest design & concept stages through to full production and assembly.We have our own tool room as well as established relationships with Local, European & Far Eastern Toolmakers. AV offer an excellent service at competitive rates and would be very grateful to quote for any new or existing mouldings, quotes are normally turned round in a 48 hour period. Therefore should you have projects for plastic automated storage and retrieval containers, A Logistic Supply Chain Distribution Tray or any other type of plastic component needing a production quotation. Please feel free to contact myself on 07739 748734 , or e-mail me at kyouens@avinjection.co.uk and I will gladly discuss your next requirement with you and the possible solutions AV Injection could offer. AV Injection can also offer in addition through our sister company Tech Tube Ltd, blow moulded products and all types of extrusion profiles in small and large volume orders . For more information visit our website www.avinjection.co.uk I look forward to be hearing from you soon.

One of Many Billion Plastic Injection Machines Injection Moulding Tooling - Testing

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New Machine - Quality Control Investment | AV Injection

New Plastic Injection Moulding Machine

AV Injection have added yet another Billion H775/200 high performance Plastic Injection Moulding machine to expand AV Injection's state of the art range of machines. This addition now brings our range of plastic injection moulding machines to 34, with the capacity to mould up to 6.2 kg in material. Billion machinery is our machine brand of choice because Billion machines allow full control in a close loop microprocessor system on all the machine movements. This process allows precision tooling for our customers products as we can use the minimum amount of pressure, temperature and speed whilst continuing to produce the highest quality products for our customers.

Manufacturing Products Quality Control Investment

AV injection have invested into the latest technology in Manufacturing Products Quality Control by using vision systems to detect any faulty products and flagging them up before they are received by the customer. The vision system picks up any discrepancies’ between a pre loaded perfect moulding and comparing it to the newly produced mouldings. This system works in milliseconds and rules out any human error or misjudgement.

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Case Study | BT

British Telecom came to AV Injection for sampling, when we initially opened the tool we noticed that there was a heavy burn stain on the fixed half texture, this sort of stain is visible on the show face of the component. To solve the problem the fixed half was sent away to have a light sand blast to bring back a fresh clean finish to the grain and texture.

                        
                                                

Do the parts consistently match the customers NEW approved sample? Has the burn mark on the tool face shown any signs of reappearing? And finally does it require any further venting etc. At the end of the production run, the tool was signed off, and a setting sheet was filled out so the exact settings can be used next time.

If you would like to discuss how we can help with your project please Contact Us.

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Case Study | Land Rover

This high tech Landrover tool came to AV Injection for initial tool trailing, the tool consisted of two hydraulic side actions/cores, one mechanical core, ten drop hot runner manifold, with a total tool weight of 6.3 tonne.

On initial start up it was apparent that there was a gate in-balance, as one impression was only 80% full. We removed the tool and re-checked the probe heights in relation to condition, seating and height position. We found that on tip was 15,000th too far forward, which restricted material flow to the cavity during the injection phase, which we corrected.

Landrover was on site during the trial and highlighted a slight gas / last point of fill which they wanted improving. We improved this by reducing lock, introducing injection profile, switching over to second stage earlier. We produced 30 samples and for Landrover for them to take away and test , all parts fitted correctly passing their stringent quality control, and we were delighted when we were commissioned for the full production run for the initial pilot build.

If you would like to discuss how we can help with your project please Contact Us.

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