Under what circumstances can a 90 ton injection molding machine bring better molding results?
2025/10/13 By le zhan

A 90 ton injection molding machine offers low clamping force, yet its size is sufficient for processing a wide range of multi-cavity consumer product parts, miniature appliance housings, and structural components. It is often an ideal choice for parts with moderate projection areas and wall thicknesses, as well as mold designs that require a stable clamping force without the burden of press inertia and space. As an injection molding machine manufacturer, I will explain to prospective users the various scenarios where a 90-ton injection molding machine can deliver superior results compared to smaller or larger machines.
90 ton injection molding machine are suitable for molding small and medium-sized parts.
90 ton injection molding machines excel at producing small and medium-sized parts, typically weighing 50-500 grams and measuring 50-200 mm. This is because their clamping force strikes a balance between sufficient pressure to seal the mold and not excessive enough to cause damage. Using a smaller injection molding machine, such as a 60-ton machine, to produce parts weighing over 300 grams often results in shortening.
This occurs when the clamping force is insufficient to hold the mold closed during injection, leading to resin leakage or mold warping, which results in an incomplete fill. Conversely, larger molding machines can over-clamp smaller parts, compressing the mold and creating flash that requires trimming. For example, a manufacturer of 350-gram PP food containers switched from a 60 ton injection molding machine to a 90-ton one, reducing shortfalls by 15% and rework time by 20%. In this case, the 90 ton machine is an ideal choice for consumer goods and automotive parts.

Balanced Injection Pressure for Medium-Viscosity Resins
Resin viscosity determines the injection pressure required to fill the mold, so a 90 ton injection molding machine is optimized for medium-viscosity resins such as PP, ABS, and PS. These resins require sufficient pressure to flow into the mold, but not too high to cause flash or deform delicate features. Most 90 ton injection molding machines offer injection pressures between 1,800 and 2,300 bar, which is precisely the pressure range required to fill the mold with medium-viscosity resins without overworking the material.
In addition, using a 90 ton molding machine to mold these resins can lead to two common problems:
Underfill: A 60 ton injection molding machine may lack sufficient pressure to push PP into a mold with thin ribs, leaving gaps.
Material degradation: A 120 ton injection molding machine may apply excessive pressure to the ABS, causing it to heat up and degrade, ultimately resulting in part discoloration.

Suitable for Multi-Cavity Molds: The stability of a 90 ton injection molding machine ensures uniform filling
Some users who require high-volume injection molding rely on multi-cavity molds to increase output per cycle. Therefore, these molds require constant clamping force and injection pressure to fill each cavity uniformly. The rigid frame and precise control system of a 90 ton injection molding machine (especially those developed in-house by Topstar) provide this stability, reducing variability between cavities.
Molds with lower clamping forces often struggle to handle molds with more than four cavities. Their less rigid frames can flex during injection, causing some cavities to fill faster than others, resulting in inconsistent part quality. However, a 90 ton injection molding machine can maintain uniform pressure in molds with two to eight cavities, even when producing complex parts.

Suitable for manufacturers who prioritize energy efficiency
Energy costs account for 15-20% of the total operating costs of an injection molding machine, and a 90-ton injection molding machine can achieve significant energy savings compared to larger machines. Most 90-ton models use 20-30% less energy than higher-clamp-force models when producing parts of the same size. They also avoid the energy waste associated with overworking larger molding machines.
For manufacturers operating 24/7, these energy savings amount to approximately 15 kWh/hour for a 90 ton injection molding machine to mold a 300-gram PP part, while a 120-ton machine consumes about 20 kWh/hour. At 0.15 kWh/kWh, this translates to an annual savings of 6,570 kWh. Furthermore, smaller molding machines may use slightly less energy, but they typically require longer cycle times, which negates any energy savings and reduces output. The 90-ton injection molding machine strikes a perfect balance, delivering high energy efficiency without sacrificing speed or quality.
Suitable for thin-walled yet structurally strong parts
Thin-walled parts are standard in packaging and lightweight consumer goods. These require precise control of injection speed and holding pressure to avoid warping or uneven wall thickness. Topstar’s 90 ton injection molding machine utilizes a proprietary control system that allows operators to fine-tune these parameters, ensuring that resin fills thin-walled parts evenly and preventing excessive cooling or overfilling. This prevents the excessive holding pressure of larger injection molding machines, which compresses the resin and creates uneven wall thickness or stress marks. It also addresses the inability of smaller injection molding machines to quickly fill thin-walled parts before the resin cools, resulting in undershot or weak structures.
The Best Choice for Small Injection Molding Applications
When your production needs align with its strengths, the 90-ton injection molding machine delivers optimal results. It is suitable for small and medium-sized parts, medium-viscosity resins, multi-cavity molds, and energy-saving goals. It avoids the drawbacks of both smaller and larger machines, making it a flexible choice for a wide range of small injection molding applications.
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