Automatic Deburring and Deflashing Machines for Injection-Moulded Plastic Parts – How to Choose the Right System
- Sean Davies
- Nov 12
- 2 min read
Updated: Nov 14
A Smarter Way to Finish Plastic Components
Injection-moulded plastic parts often leave the mould with unwanted flash or fine burrs along edges and seams. These imperfections—tiny but sharp—can cause issues in fit, safety, and appearance. Manual trimming or scraping works for prototypes, but in high-volume production it’s inconsistent, slow, and costly.
That’s where automatic deflashing and deburring systems come in. By combining controlled heat with robotic precision, these systems remove flash and smooth edges within seconds, providing a clean, uniform finish every cycle.
What Is Automatic Deburring for Plastics?
“Deburring” is usually associated with metal machining, but the same principle applies to plastics: removing thin, unwanted material left after forming. In injection moulding, that material is flash.
Automatic deburring machines use various methods—mechanical trimming, cryogenic blasting, or flame-based edge melting—to remove flash without damaging the base material. Flame systems, in particular, are fast, clean, and require no consumables or tool wear.
Why Flame-Based Systems Excel
Flame-based deburring and deflashing systems like the Rapidflame D6 burner deliver a tightly controlled gas flame to melt away flash instantly. The process:
Removes thin films and burrs without physical contact
Preserves component tolerances and surface texture
Produces no dust or particulate waste
Integrates easily with robotic arms or conveyor lines
For complex geometries or soft materials like PP, ABS, and nylon, flame treatment provides unmatched consistency compared to blades or tumbling systems.
How to Choose an Automatic Deburring Machine
When evaluating an automated deburring or deflashing solution, engineers should consider:
Part Geometry – Thin fins or deep recesses often favour flame-based removal.
Material Type – Thermoplastics respond differently to heat; verify suitability.
Cycle Time – Match burner configuration and robot speed to your line throughput.
Integration Level – Systems can be stand-alone cells or mounted directly to moulding conveyors.
Safety and Controls – Look for PLC-based flame supervision, automatic ignition, and gas flow monitoring.
A system like the Rapidflame D6 can be configured for single or multi-axis motion, ensuring precise coverage even on complex part edges.
Comparing Methods
Method | Cycle Speed | Consumables | Precision | Typical Use |
Manual trimming | Slow | Blades | Variable | Low-volume jobs |
Mechanical cutting | Medium | Blades / bits | Good | Simple parts |
Cryogenic deflashing | Fast | CO₂ pellets | Good | Small parts |
Flame deflashing | Very fast | None | Excellent | Complex / large parts |
Integrate Automation Without Disruption
Our systems can be installed as stand-alone work cells or integrated into existing robotic lines. Whether you’re upgrading a single moulding cell or automating a full production line, Rapidflame provides turnkey solutions—including burners, gas control panels, and PLC integration.
Learn More
For more information visit our main Flash and edge melting page:
For technical details or to request a quotation, contact us.
FAQ Section
Q1. Can flame deburring damage the plastic surface?
No. When correctly adjusted, the flame only melts the thin flash layer; the base part remains untouched.
Q2. How does it compare to cryogenic deflashing?
Flame systems eliminate consumables and suit larger or irregular parts that cryogenic methods can’t handle.
Q3. Can it be integrated with our existing robot?
Yes. The burner can be mounted on most industrial robots and programmed for path repetition.
Q4. What gases are used?
Typically natural gas or propane with air or oxygen, depending on required flame intensity and precision.
