What Is Injection Molding?
What is injection molding?
Injection molding is the most cost-effective way to produce plastic parts at scale. Injection molding process involves molten plastic being injected into a mold tool, then eject the solidified parts. This injection molding repeats hundreds and thousands of times quickly. The mold cost is amortized and the cost per unit is driven down to a few dollars. As injection molding process uses the same mold to produce every part, it can produce parts with consistent quality. Compared to CNC machining and 3D printing, injection molding has a wider range of materials, color, cosmetics, polishes and surface textures.
At TEAM Rapid, our injection molding services are customized services which offering prototype production molding. Our experienced engineers offer consultation on each injection molding project and move your parts from design to production. Contact us today if you need help with your injection molding projects.
How does custom plastic injection molding work?
Injection molding process require an injection molding machine, raw plastic material, and a mold. The raw plastic material is melted in the injection unit and then injected into the mold which is made out of steel or aluminum. The final parts are cooled and solidified into the mold. At TEAM Rapid, our engineers will review customer’s injection molding online inquiries. We will communicate with customers to make sure specification, requirements, lead time and price meet their need. When the injection mold is finished, we will make samples for approval. When the mold is approved, we will begin production. At TEAM Rapid, we are able to mold a wide range of injection molded parts from small medical parts to large automotive, aerospace, defense parts and more.
What are plastic injection molding materials?
At TEAM Rapid, we offer a variety of plastic injection molding materials which include ABS, ASA, CA, COPO, HDPE, LCP, LEPE, PA6, PA 6/6, PARA, PBT, PBT-PET, PC. If customers do not see the material stock, they can choose custom material and let our experienced engineers review when they have specified features, tolerances, inspection needs and required quantities.
What are variations of injection molding?
Several injection molding variations include co-injection molding, thin-wall molding, rubber injection, low-pressure plastic injection molding, inset plastic molding, outset plastic molding.
Aluminum injection mold or steel injection mold?
Aluminum injection mold or steel injection mold? It depends on budget and the desired final-product. In the past, injection molds were made from steel and were expensive. They were used only in large volume production when thousand of parts were produced. Today, aluminum mold cost less than steel injection molds. Higher grade aluminum such as QC-7 AND qc-10 is used with advanced computer equipment, it can produce thousands of parts. Compared with steel injection molds, aluminum molds provide faster cycles and turnaround. Steel molds are more expensive to build but they have longer lifespan. High grade steel such as H-13 and S-7 are tough and can withstand wear and constant pressure of plastic injection molding. Stainless steel injection molds are commonly used to produce larger and clear parts. At TEAM Rapid, we uses cutting-edge CNC machining and electrical machining to meet customers’ specifications no matter we use aluminum or steel to create molds.
How to save on injection molding?
1, Too many undercuts will increase the complexity and the tool ejection mechanisms cost. So, reduce the undercuts, it will save the cost to make injection molded pats.
2, Make an even wall thickness to avoid wall sink and voids as thinner wall will reduce cycle time and costs.
3, When designing a parts, make sure the parts are designed with a minimum draft angle of 0.5° and up to 5°.
4, Rib should be around 40% to 60% the thickness of the outer walls.
5, Bosses should be designed at a depth of 30% the wall thickness and with a 30% edge groove.
How much does plastic injection molding cost?
The material cost depends on the weight of required materials and the unit cost of that material. The weight of material is a result of the part volume and material density. The wall thickness of the part impact the cost as well. The weight of required material include the materials need to fill the channels of the mold. The size of the channels, and the amount of material is mostly determined by the thickness of the part.
The cost of injection mold depends on size of the mold and parts, the complexity of the design and the number of cavities in the mold. Initial cost may high but the price per unit is relatively low. The final cost correlates with quantity. Larger quantities will decrease overall price.
The production cost is calculated from the hourly rate and the cycle time. The hourly rate is proportional to the size of injection molding machine. Large parts require large clamping force and a more expensive machine. Certain materials require high injection pressure will require higher tonnage machines. The size of the part must comply with other machine specifications. The cycle time include injection time, cooling time and resetting time. Reducing these times can lower the production cost. Reducing the maximum wall thickness of parts and part volume can decrease the injection time and cooling time. The resetting time depends on the machine size and part size. A lager parts need larger motions from the machine to open, close, and eject the part. A larger machine needs more time to perform operations.
Why choose TEAM Rapid for injection molding services?
Injection molding a widely used manufacturing process to produce large quantities of plastic parts which are made out of thermoplastic. Injection molding process can be a rapid manufacturing process of melting plastic, injecting into a mold and then the process repeats to make thousands of even million so the same parts. TEAM Rapid offer custom injection molding services for customers in different type industries all around the world. We provide low-cost injection molded parts with high quality at a fast turnaround.
Our injection molding process starts with instant online quotes. We offer inexpensive custom molds and injection mold plastic which cost around 30% to 50% less than other plastic manufacturers. Our experienced engineers provide different options for injection mold types based on customers’ expected production cycles and the warranty. We use steel to make a plastic mold because of durability and the ability to make plastic mold complex parts. Although there are many types of steel used for a mold, and P-20 is the workhorse of the industry, we also use other types of steel according to customers’ situation and requirements. No matter your need an injection molding manufacturer to build molds or produce plastic injection molded parts, we are ready to get your projects done correctly and quickly. Contact us today to request an instant quote for your custom injection molding services projects!
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