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Injection Molding

Merit Technology possesses the latest in injection molding machinery with capacities ranging from 60 to 800 metric tons. Our precisions machines are equipped with mold temperature control, vertical and horizontal orientation, gas assistance and other optimizing features. Cassette parameter storage and host computer interface allows us to repeat the process, time and again, with complete accuracy. The synthesis of leading edge production facilities and our comprehensive knowledge of injection molding methods assure the highest quality parts in the shortest amount of time.

We schedule the setups, control the shots and make all the necessary adjustments and modifications to assure product integrity. The process can include imbedded components and subassemblies such as clips or fasteners, and we document all of the production steps to facilitate the transition to high volume manufacturing.

Low Volume Molding

Merit Technology designs, manufactures, and assembles low volume products with the same expertise, high quality standards, attention to detail, and accelerated time schedules as its high volume programs. Technologies employed for low volume programs include design, program management, CAD/CAM, advanced molding simulation and finite element analysis (FEA), stereolithography (SLA), selective laser sintering (SLS), rapid prototypes, market-entry and production tooling, decorating, and assembly.

Low volume manufacturing facilities are structured to efficiently and economically handle low annual volumes from 1000 pieces. Quick change tooling concepts reduce costs and expedite lead times. Flexible work cells minimize part handling and maintain operational flexibility, ensuring speed, efficiency, and quality in every program.

Merit Technology’ low volume operations are ISO 9001:2008, and FDA registered and operate under good manufacturing practices (GMP). These capabilities, combined with years of experience, allow Merit Technology Plastics to manage low volume programs with precision.

High Volume Molding

Merit technology’s investment into high-cavity automated systems provides our customers with an industry leading efficiency. We understand that quality is no less important then (speed) and because of this Merit technology closely monitors ever step of the production process holding to strict tolerances and unrelenting protocol.

Merit Technology has invested in state-of-the-art facilities and technologies to meet and exceed customer demand for quality, service, and value in high-volume molding applications. Advanced process controls and automation systems produce precision components with accelerated time-to-market schedules.

Ensuring part repeatability for high-volume and high-cavitation production, Merit technology' value-added work cells include automatic material supply, close tolerance injection molding presses, process monitoring systems, and custom automation systems for packaging. Merit technology also offers full-service tool design and engineering, along with complete value-added operations, including color blending at the press.

More than a "shoot-and-ship" manufacturer, Merit technology provides services to meet specific program requirements. Focused cells are available for the manufacture of clear and decorated display windows or extremely thin-walled parts common to components molded for the automotive, and telecommunications markets. Merit Technology’ in-house EMI / RFI shielding capabilities include metallized spray coatings and a robotic spraying application to ensure part consistency and minimize waste

Gas assisted Molding

Uncompromised quality while saving you money. Gas assisted injection molding will reduced tool wear, warping found in high pressure parts and the amount of material used in each part.

Gas-assist injection molding is a process that utilizes an inert gas (normally nitrogen) to create one or more hollow channels within an injection-molded plastic part. At the end of the filling stage, the gas (N2) is injected into the still liquid core of the molding. From there, the gas follows the path of the least resistance and replaces the thick molten sections with gas-filled channels. Next, gas pressure packs the plastic against the mold cavity surface, compensating for volumetric shrinkage until the part solidifies. Finally, the gas is vented to atmosphere or recycled.

Gas-assist injection molding has been around for well over 10 years and many people have had concerns over patent, rights and royalty fees. Within the past few years, some of the original patents have expired. And now, gas-assist injection molding is widely practiced. Design engineers and processors alike are discovering that this technology is an attractive option for certain applications and offers many benefits. It is the responsibility of the manufacturer to ascertain that their practice or technology is not covered by current patents.

Merit Technology gives a succession of benefits, leading to higher quality products at less cost. You'll benefit from a significant reduction in clamp tonnage because our process does not completely fill the mold.

Packing the part with gas pressure will use approximately 1/5 of the total pack out pressure usually needed in conventional molding. Since high-pressure hydraulics are no longer needed to pack the part, considerably less energy is consumed and you gain greater dimensional stability due to lower molded in stresses. In fact, in some cases you may be able to use lower cost mold building materials such as aluminum instead of P-20.

You'll also benefit from less machine wear, tool wear and parting line problems. Hot-runners can be eliminated due to increased flow length. Overall, you reduce weight, production time and cost, as you gain major benefits.

1. The process begins when a "short shot" of thermoplastic is injected into a mold, partially filling it with a predetermined amount of resin.
2. A resin/gas shut off valve is used to isolate the resin in the mold from the barrel.
3. Using either a nozzle or gas pins, nitrogen is injected into the center of the hot resin, following the path of least resistance it forms hollow channels and directs the resin to the last area of the mold to fill.
4. As the gas expands in the cavity, forcing the plastic in front of it, all of the surfaces receive an equal pressure creating an even "pack out" of the part. This brings the following benefits: shortened cooling cycle, elimination of sink marks and improved dimensional stability.
5. The nitrogen gas is vented either through a sprue break, if gas was injected through the nozzle, or back through the self-venting pins if injected by pins.

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