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tools:imported:portable_injection_molder_tool_guide [2023/02/18 19:50] – created - external edit 127.0.0.1tools:imported:portable_injection_molder_tool_guide [2023/04/11 21:33] – [Portable Injection Molder] cookienoyousei
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-Protohaven+====== Portable Injection Molder (please check, needs manual)====== 
 +  * Model: [[https://community.preciousplastic.com/academy/build/injection|Precious Plastic V1 Injection Molder]] 
 +  * Manufacturer: [[https://PreciousPlastic.com|Precious Plastic]] 
 +  * Manual: [[https://example.com|Link]]
  
 +The Injection machine is a very simple concept, it heats the plastic and with pressure fills a mold. You can create really beautiful and well finished objects, and if your mold is well made then you can keep a consistent high quality across your production.
  
 +{{tools:portable_injection_molder_tool_guide_image2.png|400}}
  
-Portable Injection Molder 
  
 +====== Requirements ======
  
 +[[https://www.protohaven.org|Area]] clearance or class equivalent is required before use.
  
-Precious Plastic V1 Injection Molder+====== Warnings ======
  
 +🚫 Don’t burn the plastic
  
 +⚠️ Beware of heat and molten squeeze out\\
 +⚠️ Remember monkey tight not gorilla tight
  
-====== Tool Guide ====== 
  
- +See the [[#tool-safety|Safety Section]] for more information.
- +
-The [[#h.v8apgf1liab|Setup]], [[#h.xuj6jcon719r|Operation]], and [[#h.dqiyr7wmqe1e|Cleanup]] Checklists of this guide are what instructors use to ensure that you can use the equipment according to community expectations. +
- +
- +
- +
-The Injection machine is a very simple concept, it heats the plastic and with pressure fills a mould. You can create really beautiful and well finished objects, and if your mould is well made then you can keep a consistent high quality across your production. +
- +
- +
- +
-{{tools:portable_injection_molder_tool_guide_image2.png}} +
- +
- +
----- +
- +
-===== Usage Highlights ===== +
- +
-[[https://www.google.com/url?q=https://www.protohaven.org/equipment/&sa=D&source=editors&ust=1676742602794397&usg=AOvVaw24ue1MfNPc-OVOrpC9ECBR|Precious Plastic Machines Clearance]]  or [[https://www.google.com/url?q=https://www.protohaven.org/product-category/classes-events/&sa=D&source=editors&ust=1676742602794830&usg=AOvVaw26wWZ0zXdGS6lgFs1-H2na|Class Equivalent]]  Required Before Use +
- +
- +
- +
- +
- +
-|==== SAFETY ====                                |==== CARE ====                                                                                                                                                                           |==== CLEANUP ====         | +
-|1. Wear appropriate PPE, a respirator is advised|1. Preheat before moving the plunger                                                                                                                                                     |1. Unplug the machine     | +
-|2. Don’t burn the plastic                       |2. Remember monkey tight not gorilla tight                                                                                                                                               |2. Sweep the debris       | +
-|3. Beware of heat and molten squeeze out        |3. Submit a [[https://www.google.com/url?q=http://protohaven.org/maintenance&sa=D&source=editors&ust=1676742602799288&usg=AOvVaw1J6q1jr2f_vaoGJA48zlYH|maintenance request]] when needed.|3. Return the checkout kit| +
- +
- +
- +
- +
- +
- +
----- +
- +
- +
- +
-===== Personal Protective        Equipment ===== +
- +
-Face Masks & Cleaning Kits are required at all times during the Pandemic. +
- +
- +
- +
-At the Portable Injection Molder, Safety Goggles and Heat Resistant Gloves (preferably smooth leather so plastic will not stick) are also required. +
- +
- +
- +
-Clothing and closed-toed shoes (preferably boots) must be of natural materials that will burn quickly and not melt to skin (i.e. cotton, denim, leather). +
- +
-{{tools:portable_injection_molder_tool_guide_image5.jpg}}{{tools:portable_injection_molder_tool_guide_image3.jpg}} +
- +
-{{tools:portable_injection_molder_tool_guide_image6.png}} +
- +
- +
-----+
  
 ===== Tool Anatomy ===== ===== Tool Anatomy =====
- 
- 
- 
-==== MACHINE ANATOMY ==== 
  
 {{tools:portable_injection_molder_tool_guide_image1.png}} {{tools:portable_injection_molder_tool_guide_image1.png}}
- 
- 
  
   - Lever - Controls the position of the plunger.   - Lever - Controls the position of the plunger.
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   - Maintenance Tag - Manually tracks the usability status with Green/Yellow/Red cards   - Maintenance Tag - Manually tracks the usability status with Green/Yellow/Red cards
  
- +==== Control Panel  ====
- +
- +
- +
-==== CONTROL PANEL  ====+
  
 {{tools:portable_injection_molder_tool_guide_image4.png}} {{tools:portable_injection_molder_tool_guide_image4.png}}
- 
- 
  
   - Power Switch   - Power Switch
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   - Set Temperature   - Set Temperature
  
- +==== Check-out Kit ====
----- +
- +
-====  ==== +
- +
-==== CHECK-OUT KIT ====+
  
   - Leather Gloves —  To safely handle hot components   - Leather Gloves —  To safely handle hot components
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   - Utility Knife — For refinement of excess material   - Utility Knife — For refinement of excess material
   - Precious Plastic Coins — To mark the final piece with the appropriate number plastic (you’ll need a soldering iron to heat them before making a mark)   - Precious Plastic Coins — To mark the final piece with the appropriate number plastic (you’ll need a soldering iron to heat them before making a mark)
- 
- 
  
 ===== Tool Safety ===== ===== Tool Safety =====
 +==== Personal Protective Equipment ====
  
-==== COMMON HAZARDS ==== +At the Portable Injection Molder, Safety Goggles and Heat Resistant Gloves (preferably smooth leather so plastic will not stick) are also required.
- +
-Be cautious of burning yourself!+
  
 +Clothing and closed-toed shoes (preferably boots) must be of natural materials that will burn quickly and not melt to skin (i.e. cotton, denim, leather).
 +Respirators are recommended.
  
 +{{tools:portable_injection_molder_tool_guide_image6.png}}
 +==== Common Hazards ====
  
 +**Be cautious of burning yourself!**
   * Avoid contact with molten plastic at all times   * Avoid contact with molten plastic at all times
   * Be careful while opening the nozzle, plastic can drip out immediately after opening!   * Be careful while opening the nozzle, plastic can drip out immediately after opening!
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   * Avoid contact with heated parts like: injection barrel, nozzle, plunger and the mould, which will heat up over time!   * Avoid contact with heated parts like: injection barrel, nozzle, plunger and the mould, which will heat up over time!
  
- +**Worn connection points**
- +
-Worn connection points +
- +
- +
 Make always sure your nozzle connectors are in a good condition! Defective connection points can enable the plastic to squeeze out from the barrel under high pressure and cause risk to health! Make always sure your nozzle connectors are in a good condition! Defective connection points can enable the plastic to squeeze out from the barrel under high pressure and cause risk to health!
  
- +===== Setup =====
- +
- +
- +
- +
- +
- +
- +
- +
----- +
- +
- +
- +
-===== Initial Setup =====+
  
 There are some physical limitations which have to be considered when using the injection machine.  There are some physical limitations which have to be considered when using the injection machine. 
- 
- 
  
 The volume determines the maximum volume of the cavity together with gate, runners and sprue you can fill. The injection pressure determines how fine your details can be and what is the minimum achievable wall thickness.  The volume determines the maximum volume of the cavity together with gate, runners and sprue you can fill. The injection pressure determines how fine your details can be and what is the minimum achievable wall thickness. 
- 
  
  
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 Pressure: 44bar Pressure: 44bar
  
 +  - Plug in the machine to the transformer, then plug in the transformer to the outlet
 +  - Power on the heat control to preheat and clear the barrel
 +  - Set the temperature to 20° more than desired for production
 +  - Wait for at least 20 minutes before moving the plunger—never force movement on the plunger when cold
 +  - Turn down the temperature
 +  - Fill the barrel with desired plastic
 +  - Wait another 15 minutes for the plastic to melt
 +  - Press the first batch of plastic to get rid of plastic from previous sessions
 +  - Begin production! The machine is now warm and ready to use with your molds
  
 +**Making a Mold**
  
-====  ====+The most common material for small molds is aluminum. It’s easy to machine and has a high lifespan. Here we have an overview of options from Precious Plastic:
  
 +^Material ^Application ^Accuracy ^Costs ^Lifetime (shots) ^
 +|Wood/MDF  |Not recommended (plastic sticks to mould)|low-med |<$150  |—   |
 +|Acrylic      |Demo/prototype   |low-med |<$150  |5-10               |
 +|Silicone Casting       |Prototype           |low     |<$150  |<20    |
 +|SLA Printing\\ (high temp resin)|Prototype, Sm Series       |med     |>$250  |<100       |
 +|Cast Aluminum      |Molds for organic geometry   |low-med |<$150  |<2,000-10,000|
 +|Machined Aluminum      |Sml-Med Series           |high    |>$250  |<2,000-10,000|
 +|Lasercut Steel       |Prototyping/Lg Series     |med     |<$150  |<100,000   |
 +|Plasma Cut Steel       |Prototyping/Lg Series     |low-med |<$150  |<100,000  |
 +|Welded Steel           |Prototyping/Lg Series    |low-med |<$150  |<100,000           |
 +|Machined Steel         |Lg Series            |high    |>$1,000|<100,000           |
  
  
-|==== SETUP CHECKLIST  ====\\ \\ - Plug in the machine to the transformer, then plug in the transformer to the outlet\\ - Power on the heat control to preheat and clear the barrel\\ - Set the temperature to 20° more than desired for production\\ - Wait for at least 20 minutes before moving the plunger—never force movement on the plunger when cold\\ - Turn down the temperature\\ - Fill the barrel with desired plastic\\ - Wait another 15 minutes for the plastic to melt\\ - Press the first batch of plastic to get rid of plastic from previous sessions\\ - Begin production! The machine is now warm and ready to use with your moulds|+===== Operation ===== 
 +  - Fill the barrel with desired plastic, leaving roughly 0.5” to the top of the opening 
 +  - Press the lever into the barrel 
 +  - Pull the lever up every 5 to 10 minutes and add more plastic, always careful to leave a small opening at the top 
 +  - Wait at least 10 minutes 
 +  - Secure the mold to the nozzle (be quick or plastic will start to flow out!) 
 +  - Preheat the base plate of the mold with a propane torch 
 +  - Pull the lever down as far as possible 
 +  - Hold the downward position for at least 5-10 seconds 
 +  - Detach the mold from the nozzle 
 +  - Pull the lever to the furthest upright position 
 +  - Close the nozzle with its cap 
 +  - Let the mold cool for 10-15 minutes before opening 
 +  - Heat the appropriate Precious Plastic coin with a soldering iron 
 +  - Stamp your piece!
  
- 
- 
- 
- 
- 
----- 
- 
- 
- 
-MAKING A MOULD 
- 
- 
- 
-The most common material for small moulds is aluminium. It’s easy to machine and has a high lifespan. Here we have an overview of options from Precious Plastic: 
- 
- 
- 
- 
- 
-|Material                           |Application                              |Accuracy|Costs  |Lifetime (shots)   | 
-|Wood/MDF                           |Not recommended (plastic sticks to mould)|low-med |<$150  |—                  | 
-|Acrylic                            |Demo/prototype                           |low-med |<$150  |5-10               | 
-|Silicone Casting                   |Prototype                                |low     |<$150  |<20                | 
-|SLA Printing\\ \\ (high temp resin)|Prototype, Sm Series                     |med     |>$250  |<100               | 
-|Cast Aluminum                      |Moulds for organic geometry              |low-med |<$150  |<2,000-\\ \\ 10,000| 
-|Machined Aluminum                  |Sml-Med Series                           |high    |>$250  |<2,000-\\ \\ 10,000| 
-|Lasercut Steel                     |Prototyping/Lg Series                    |med     |<$150  |<100,000           | 
-|Plasma Cut Steel                   |Prototyping/Lg Series                    |low-med |<$150  |<100,000           | 
-|Welded Steel                       |Prototyping/Lg Series                    |low-med |<$150  |<100,000           | 
-|Machined Steel                     |Lg Series                                |high    |>$1,000|<100,000           | 
- 
- 
- 
- 
----- 
- 
-=====  ===== 
- 
-===== Basic Operation ===== 
- 
-====  ==== 
- 
- 
- 
-|==== OPERATION CHECKLIST ====\\ \\ \\ \\ - Fill the barrel with desired plastic, leaving roughly 0.5” to the top of the opening\\ - Press the lever into the barrel\\ - Pull the lever up every 5 to 10 minutes and add more plastic, always careful to leave a small opening at the top\\ - Wait at least 10 minutes \\ - Secure the mould to the nozzle (be quick or plastic will start to flow out!)\\ - Preheat the base plate of the mould with a propane torch\\ - Pull the lever down as far as possible\\ - Hold the downward position for at least 5-10 seconds\\ - Detach the mould from the nozzle\\ - Pull the lever to the furthest upright position\\ - Close the nozzle with its cap\\ - Let the mould cool for 10-15 minutes before opening\\ - Heat the appropriate Precious Plastic coin with a soldering iron\\ -  Stamp your piece!| 
- 
- 
----- 
- 
-=====  ===== 
  
 ===== Cleanup ===== ===== Cleanup =====
- 
- 
  
 It’s important to clean the area of all leftover plastic at the end of use. If not, this will lead to cross-contamination since the next person won’t be able to identify which type of plastic was used! It’s important to clean the area of all leftover plastic at the end of use. If not, this will lead to cross-contamination since the next person won’t be able to identify which type of plastic was used!
  
 +  - Power off the heat control
 +  - Unplug the transformer and the machine
 +  - Clean the area from all leftover plastic
  
 +==== Scrap Breakdown ====
  
 +Protohaven is working to carefully measure and monitor the intake of #5 Plastic. If you wish to add to our collection, please notify someone on duty to help track the new input or attend one of our Shredding Sunday Events!
 + 
 +==== Maintenance Requests ====
 +If you encounter any of the issues listed in the Inspection area or have any other issues with the tool not working properly:
  
- +  * Update the physical Maintenance Tag at the machine 
-|==== CLEANUP CHECKLIST ====\\ \\ - Power off the heat control\\ - Unplug the transformer and the machine\\ - Clean the area from all leftover plastic\\ - Note any maintenance needs or concerns on the tag and at [[https://www.google.com/url?q=http://protohaven.org/maintenance&sa=D&source=editors&ust=1676742602828465&usg=AOvVaw1OroP22yOST-9L_kIrYKxf|protohaven.org/maintenance]]| +    * 🟢Green can be used without issue 
- +    * 🟡Yellow can be used withcaution 
-====  ==== +    * ⛔Red cannot be used without hazard to either the user or the equipment 
- +  * Record issues at [[https://protohaven.org/maintenance|protohaven.org/maintenance]]. This notifies our staff and volunteer maintenance crew of any issues.
-==== SCRAP BREAKDOWN ==== +
- +
- +
- +
-Protohaven is working to carefully measure and monitor the intake of #5 Plastic. If you wish to add to our collection, please notify someone on duty to help track the new input or attend one of our Shredding Sunday Events!  +
- +
- +
- +
-==== MAINTENANCE REQUESTS ==== +
- +
- +
- +
-  - Update the physical Maintenance Tag at the machine +
- +
-  * Green can be used without issue +
-  * Yellow can be used with caution +
-  * Red cannot be used without hazard to either the user or the equipment +
- +
-<HTML><ol start="2"></HTML> +
-<HTML><li></HTML>Record issues at protohaven.org/maintenance. This notifies our staff and volunteer maintenance crew of any issues<HTML></li></HTML><HTML></ol></HTML> +
- +
- +
----- +
- +
-=====  =====+
  
 ===== Troubleshooting ===== ===== Troubleshooting =====
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   * If nozzle is not reaching appropriate temperature during setup, a supplemental torch may be used to carefully warm the metal components—be sure not to burn plastic or other non-metal elements   * If nozzle is not reaching appropriate temperature during setup, a supplemental torch may be used to carefully warm the metal components—be sure not to burn plastic or other non-metal elements
  
-====  ==== 
  
 ==== INCOMPLETE FILL ==== ==== INCOMPLETE FILL ====
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   * Add air vents no deeper than 0.1 mm to avoid flash   * Add air vents no deeper than 0.1 mm to avoid flash
   * Increase the gate size to decrease the injection pressure needed   * Increase the gate size to decrease the injection pressure needed
- 
- 
  
 ==== FLASH ==== ==== FLASH ====
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   * Check that your mold is flat   * Check that your mold is flat
   * Decrease the material temperature and/or the injection pressure   * Decrease the material temperature and/or the injection pressure
- 
- 
  
 ==== SINK MARKS ==== ==== SINK MARKS ====
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   * Decrease the material temperature   * Decrease the material temperature
- 
- 
  
 ==== AIR BUBBLES ==== ==== AIR BUBBLES ====
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   * Pre-dry your plastic material before melting to reduce moisture content   * Pre-dry your plastic material before melting to reduce moisture content
   * Increase the injection pressure   * Increase the injection pressure
- 
  
  
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-===== Staff Use =====+====== Staff Use ======
  
-==== AUTHORIZED MAINTENANCE CREW ONLY ====+|⚠️ AUTHORIZED MAINTENANCE GROUP ONLY|
  
 If you are part of the maintenance group please log on to the #maintenance channel of our Discord server to: If you are part of the maintenance group please log on to the #maintenance channel of our Discord server to:
- 
  
  
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   * Review complete Maintenance Logs for each machine   * Review complete Maintenance Logs for each machine
   * Generally chit-chat about maintenance   * Generally chit-chat about maintenance
 +
  
 ===  === ===  ===
  
 +===== Tools =====
  
- +The following should be in a Maintenance tool kit for the....
-|=== Hippocratic Oath ===\\ \\ \\ \\ * Start with the Manual\\ * Ask questions\\ * Know your limits\\ * Do no harm\\ * Document your actions| +
- +
- +
- +
- +
- +
- +
- +
- +
- +
  
  
 +  * item1
 +  * item2
  
  
 +===== Regular Maintenance =====