Author: regan

Av Injection was approached to look at a solution in Plastic Injection Moulding using a raw material to make a vehicle-barrier. The material used has to be able to be Injection Moulded and at the same time be able to meet the customer high specification. The application is a barrier to stop vehicles driving into restricted areas. Test was carried out and can be seen on YouTube upon request. The design of the mould was very important and the raw material was put to the test to withstand the extreme pressures and impact tests. AV Injection were able to solve all the aspects of this project in finding the correct raw material, and getting the design of the mould tool to be able to produce a high-quality part to meet the extreme impact forces needed. To add to the service AV Injection were able to make the product with a very high standard outer surface finish. For further information on any of our case studies or if you would like to discuss your project please contact us.

AV Injections were approached to design a mould tool to make a Balloon Knotter component for a very special TV programme. Tomorrows World and one of the presenters was Raymond Burke? The project had to be kept under cover, no one was to know what the component was to be used for, and as a consequence confidentiality agreements (now expired) were signed. We made the mould tool for the Balloon Knotter in our in-house Tool Room tested it and handed over the completed project to the Tomorrows World team at the Television studio Finally the show aired and as usual Raymond Burke presented and introduce several items and asked the live audience and viewers what they thought the items were used for? No one guessed correctly that the very secretive product was in fact just a Balloon Knotter!. For further information on any of our case studies or if you would like to discuss your project please contact us.

AV Injection has now been working alongside our client with a very high-quality range of products for a number of years. The client is a market-leading brand that is certainly visible in most major DIY stores, both in the UK and internationally. The client specialise in wall fixings, know commonly as RawlPlugs. So if you’ve ever drilled a hole to hang a shelf etc, chances are that you used our clients product. Our client required a complex multi-cavity tooling using a wide range of different materials. With our in-house Tool Room, we were able to keep the tooling and moulds in good condition, maximising the full impressions of the tooling and keeping the production cycle at its maximum. We continue to Plastic Injection Mould for the client significant amounts of their product range, we also provide them with JIT storage and logistics. For further information on any of our case studies or if you would like to discuss your project please contact us.

An order from a premier global business specialising in rail and air transportation. Naturally AV Injections were flattered to have been chosen as the partner assisting in the design and manufacture of a flame retardant component to be used in one of their transportation vehicles. Once the tool had been designed and manufactured in hardened steel, trial samples were required, and through the use of the latest Injection Moulding machines, applying very precise controls in injection pressure and injection speeds. AVI was able to produce very precise sample products in the required Flame Retardant material. For further information on any of our case studies or if you would like to discuss your project please contact us.

AV injection purchased a Billion 1000 tonne Injection Moulding machine to be able to Injection mould a product for a Global Garden Equipment customer. 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.

A Major telecommunication company came to AV Injection for Product 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. The tool was then closely monitored for the following criteria: Do the parts consistently match the customer’s 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. For further information on any of our case studies or if you would like to discuss your project please contact us.

AVI was Naturally excited when we received an inquiry from a Leading licensed soft Drinks partner. Whilst the project was simple, we produced the tool from our in-house Tool Room, ensuring that the simple Soft Drinks giant savings bottle top was 100% perfect. Producing mass plastic injection moulded parts is simply provided that you are able to minimise the production cycle, which is hugely important in making our services not only quality competitive but also prices competitive.. For further information on any of our case studies or if you would like to discuss your project please contact us.

An Automotive high-tech tool came to AV Injection for initial tool trailing, the tool consisted of two hydraulic side actions/cores, one mechanical core, ten drops hot runner manifold, with a total tool weight of 6.3 tonnes. On initial start up it was apparent that there was a gate in-balance, as one impression was only 80% full. AVI removed the tool and re-checked the probe heights in relation to a 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. The Client 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 the second stage earlier. We produced 30 samples and for the Client 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. For further information on any of our case studies or if you would like to discuss your project please contact us.