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Home / What improvements can all electric injection molding machine bring to thin-walled parts?

What improvements can all electric injection molding machine bring to thin-walled parts?

2025/08/15 By le zhan

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All electric injection molding machines replace hydraulic drives with servo-driven motors, fundamentally changing how the machine controls position, speed, pressure, and timing. For thin-walled parts, these control advantages translate into fewer short shots, a more uniform appearance, tighter dimensional tolerances, and higher production yields.

Specifically, Topstar’s all electric injection molding machines offer improvements in five practical dimensions: higher positioning and pressure accuracy; faster, repeatable injection and holding pressure profiles; greater energy efficiency and stability; cleaner operation and lower maintenance costs; and enhanced process monitoring and integration to ensure quality. These improvements enable faster operation of thin-wall molds with improved consistency.

All electric injection molding machines offer precise pressure and position control

Thin-walled parts require extremely high precision. During the short, high-speed filling process required for thin-wall injection molding, even slight deviations in screw position, injection speed, or holding pressure can result in visible weld lines, flash, or short shots. All-electric injection molding machines offer more precise position and pressure control because the electric drive provides direct, real-time control of the injection screw and clamping mechanism. In contrast, hydraulic systems rely on pressure-compensated flow and proportional valves, which introduce hysteresis and slow down the feedback loop.

Topstar’s all electric injection molding machines can achieve positioning repeatability of ±0.01 mm and pressure control resolution of less than 0.5 bar on the injection axis. In production, this accuracy reduces variations in shot weight and instantaneous cavity pressure. For example, in injection molding, migrating a 0.6 mm wall-thick PP container from a hydraulic to an all-electric machine reduced the standard deviation of shot weight by approximately 40% and the dimensional variation across 10 cavities by approximately 30%. These values were achieved only when the equipment was paired with a high-performance feed screw and optimized nozzle design.

All electric injection molding machines offer precise pressure and position control

Faster, Repeatable Injection Profiles and Cycle Optimization

Speed is also crucial for thin-wall injection molding. Thin-walled parts require extremely fast injection speeds to prevent premature solidification at the gate and ensure complete cavity filling before skin formation occurs. Here, all electric injection molding machines again hold the advantage. Electric screw and linear motors deliver high-speed acceleration and deceleration with precise timing, enabling controlled peak injection speeds and near-instantaneous changeovers.

Topstar TEll all electric injection molding machine typically achieve peak injection accelerations two to four times higher than comparable hydraulic presses while maintaining precise position control. This capability enables molders to use very short fill times without sacrificing repeatability. Furthermore, many hydraulic presses exhibit drift during the first few shots after a mold change or temperature fluctuation. All electric platforms recover setpoints within a few cycles, resulting in more predictable ramp-up and shorter run-to-quality times.

All electric injection molding machines offer greater energy efficiency, stability, and consistent melt conditions

Thermal management is critical for thin-walled parts, as melt temperature and viscosity directly impact fillability and skin quality. All-electric presses offer not only improved energy efficiency but, more importantly, improved thermal stability. From an energy perspective, servo-driven motors convert electrical energy into kinetic energy, consuming less energy than hydraulic pumps operating under continuous load. Our research data shows energy savings of 30% to 60%. In addition to lowering electricity costs, lower machine heat generation also reduces the heat load within the production cell.

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On the other hand, thermal stability directly improves part consistency. When the injection molding machine‘s barrel, nozzle, and mold are thermally stable, the resin’s shear history and melt temperature remain consistent from shot to shot. Furthermore, without hydraulic oil, melt temperature deviation can be reduced from ±3–5°C with traditional hydraulic systems to ±0.5–1.5°C with fully electric systems. This reduces undershot shots and fluctuations in surface quality.

Cleaner operation, reduced maintenance, and lower contamination risk

Traditional injection molding machines consume large amounts of hydraulic oil, resulting in maintenance downtime and contamination risks associated with components such as pumps and valves. The oil circulating in the hydraulic system can leak, contaminating tools or generating fumes. All electric injection molding machines have fewer fluid interfaces, resulting in fewer leak points and reducing the potential for contaminants to transfer to the mold or molded parts. In the production of high-cavitation, thin-wall parts, such as food packaging or medical components, the reduced risk of oil or particle contamination is a significant quality advantage, simplifying certification and cleaning procedures.

Data from electric injection molding machines in production typically indicate that less preventive maintenance is required for the core motion system. In contrast, hydraulic presses require constant attention to seals, filters, and pumps to ensure optimal performance. As a result, average monthly maintenance hours for all-electric production lines are typically 20% to 40% lower.

Advanced Process Monitoring, Ensure Thin-Wall Quality

Topstar’s all electric injection molding machines, under a unified control system, capture higher-fidelity process data—screw position at millisecond intervals, cavity pressure and temperature synchronized with motion events, and energy consumption per shot.

For thin-wall parts, high-resolution cavity pressure sensors, combined with the injection molding machine’s fast response time, enable closed-loop cavity pressure control, allowing for adjustments to holding pressure and cooling on a shot-by-shot basis. This reduces wall thickness variation and minimizes warpage. At the same time, predictive maintenance and faster mould troubleshooting can be performed directly within the injection moulding machine’s control panel, allowing engineers to correlate environmental conditions, machine drift, and part geometry deviations, and make adjustments on the fly to ensure production quality.

Delivering thinner, higher-quality thin-walled parts

From a practical production perspective, manufacturers who switch to all electric injection molding machines for thin-wall production typically experience increased output, reduced cycle variability, and a lower total cost of ownership, thanks to energy savings and reduced maintenance costs. This allows them to produce thinner, higher-quality parts at competitive cycle times.

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