1" x 20 cm Metal Cartridge

The cartridge is a fundamental componente in the process of plastic solar injection.

Supplies

The components required are all standard :

Two sides threaded 1" tube x 20cm
Two 1" to 1/2" reducers
Piston
Two standard 3/4" copper caps
A 3/4" metal tube
One 1/2" cap

Tools needed :

Metal file
Metal saw
Hammer for securing components
Sandpaper for polishing surfaces
Dril + 3mm metal drill bit

Step 1: Clean the Metal Tube

Use the metal file to ensure the Two sides threaded 1" tube ends are clean and free of burrs.

Step 2: Creating the Piston

Creating the Piston (3)

With a metal saw, cut the 3/4" metal tube with 20mm. Clean the edges with a metal file.

Assemble the 20mm 3/4" metal tube with the two standard 3/4" copper caps, use the hammer and a flat surface.

Step 3: Ajust Piston to Metal Tube

For optimal performance, it is crucial to adjust the piston using sandpaper to smooth the copper caps. Ensure that the piston moves smoothly within the tube, and check for any potential obstructions or irregularities that may affect its functionality.

Step 4: Cap Hole

One of the necessary operations is to drill a 3mm hole using a metal drill bit and a power drill. This hole is made in the 1/2" bronze cap. The hole is intended for inserting the temperature probe, and for safety reasons, it helps prevent pressure build-up in the tube.

Step 5: Assemble All Components

For the assembly, begin by inserting the piston into the 1-inch tube, ensuring that the piston sits snugly at the entrance. Next, assemble the two 1" to 1/2" reducers, and finally, attach the 1/2" brass cap.

Step 6: Using the Cartridge

Fill the cartridge, already equipped with the piston and one of the connected reducers.
Connect the second reducer, if possible, fill the reducer.
Seal with the 1/2" bronze cap, ensuring the cap has a vent hole to prevent issues during heating.
Attach the cartridge to the mold.
Connect the cartridge with the mold to the manual press.
With the press, push the piston to perform the injection.