During a production run, an injection moulding machine repeats the same cycle thousands, even tens of thousands, of times. However, that doesn’t necessarily mean that every component will meet its specification.
Small changes during production can affect a component’s dimensions, appearance and performance. The resulting component may not fit an assembly, form a reliable seal or meet its approval requirements.
The best way to ensure consistent quality in injection moulded components is to implement controls across the entire manufacturing process. At Talisman Group, we build quality into the project from design and tooling to production, inspection and traceability.
Define what a conforming component looks like
Before production, you need a manufacturing specification covering the component’s material, dimensions, tolerances, finish and functional requirements. It should identify critical features, how you’ll assess them and any sample approval or sector-specific documentation you need.
This gives the manufacturing and quality teams an objective standard, rather than asking them to decide whether a part simply ‘looks right’.
The design and tooling stage is also your best opportunity to prevent recurring problems. We use CAD, simulation and 3D print modelling to help validate component and tool designs before we begin high-volume production.
Establish and control the moulding process
Once we’ve approved a component, the next challenge is to reproduce it throughout the production run and on future orders.
Material condition, temperature, injection pressure and speed, holding pressure, cooling and cycle times all influence how the plastic fills the tool and holds its shape. The ideal settings depend on the polymer, tool, component geometry and performance requirements.
The manufacturing specification records the required process settings. Our operators can access it at the machine and use programmable controls to run the process consistently. Robots and sprue pickers carry out the same handling tasks during each cycle, reducing variation in handling and cycle time. Our quality-trained operators follow the specification, monitor production and act when something isn’t right.
Inspect and measure components
We carry out first-off and last-off checks against the manufacturing specification. The first-off check examines components from the beginning of the run, while the last-off check helps us identify any variation that may have developed by the end.
A visual check can identify surface defects, but it can’t confirm every dimensional requirement. Our in-house coordinate measuring machine (CMM) and dedicated metrology engineer allow us to check component features against the specified geometry.
A separate quality team supports our operators with inspection, verification and the wider quality system.
Complete the required approval documentation
Customers in some sectors need formal evidence before approving parts for volume production. We can support Initial Sample Inspection Reports (ISIRs), First Article Inspection Reports (FAIRs) and the Production Part Approval Process (PPAP).
Depending on your requirements, a submission may combine dimensional results with manufacturing and approval records to demonstrate that the component and process meet the agreed specification.
Maintain traceability and use the data
Our quality records don’t just disappear once your batch leaves our factory. We’ve implemented reliable traceability and data-recording processes that help connect your components with the relevant production and inspection information.
If a concern arises, these records support a focused investigation. They can also reveal trends and guide improvements before variations cause a problem.
Each of our three UK sites holds ISO 9001 certification, providing a quality management framework based on controlled processes and continual improvement. Our Malvern facility also holds BRCGS Packaging Materials certification.
Choose an injection moulding partner that controls quality
Consistent quality depends on controlling each stage of production, from design and tooling to inspection and traceability.
At Talisman Group, our documented processes, trained operators, quality team, inspection capabilities and traceability systems help us manufacture injection moulded components to your requirements. If you need a partner who can support your project from design through to repeat production, get in touch with us today.