One of the most widely used components in thick wall injection molding applications

Thinning wall injection molding is an uncommonly used type of traditional direct injection molding which focuses on producing extremely thin, lightweight plastic components that are both durable and cost-effective. By focusing on producing extremely thin, lightweight material, these types of machines enable manufacturers to reduce material use and manufacturing time while simultaneously improving product quality and reducing waste by a large margin. Longer cycle times mean higher production and lower material costs per unit, which leads to higher profit margins for both manufacturers and wholesalers. In fact, many in the molding industry often term these types of systems "thin-wall machines" to emphasize the key role they play in both the injection and drying processes.

One of the most widely used components in thick-wall injection molding applications is the thin-wall accessory assembly or simply called the battery covers. These plastic accessories fit inside the injector chamber and help prevent damage to the injection area by offering a barrier between the interior of the mold and the exterior surfaces. They are typically made from high-impact plastics such as polycarbonate and aluminum with rubberized finishes to provide a non-abrasive surface for long-term service life. These battery covers are often visible from the outside and are often complemented by small lugs or ports to help prevent inadvertent leaks from seeping into the mold cavities. While these components play an important role in the operation of injection equipment, they are rarely visible to the naked eye, requiring an appropriately themed visual for the injection process.

A close relative of the battery covers is the integral cover, which is essentially a thick plastic slice used to cover and protect components during the casting process. Often referred to as a "drip liner," this plastic component helps to prevent excess spray back from affecting the internal parts of the mold. It also provides an extra layer of insulation against moisture, making it useful for tempering parts to help prevent cracking. Injection wall thicknesses are typically measured in thousandths of an inch, although most parts will be injected at about two hundredths of an inch, using a similar method to the integral model. In addition to being visible, part covers are useful in helping to identify parts that may be differently colored during the casting process. Finally, part identification is helpful in ensuring that no two parts are the same, a process commonly referred to as "gearing."