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Before every plastic injection mould cutting, it is necessary to do its DFM analysis to make sure it can be injected perfect by finding whether there is any design improvements needed. Success is defined by outcome,the video is the example work that mattered that can help you have a understanding on what exact the process is. Contact us now to get a free DFM report if you are developing any new product.
Injection Molding Processes
Rapid injection mold
Rapid injection mould with quick lead times, ideal for prototyping and small quantity production that is for design validation to bridge production.
Overmolding
The overmolding process let you combine multiple materials into one part. One material, usually a thermoplastic elastomer (TPE/TPV/TPU) is molded onto a second material which is often a rigid plastic. Or to overmould metal inserts inside the plastics.
Two-color mold
Two-color injection molding is a manufacturing process used when referring to mold two materials/colors into one plastic part,which is a technology blends two materials or two different colors into one ending plastic part by using 2k injection molding machine.
Mass production injection mold
Mass production Injection molding is a manufacturing process that involves injecting molten material into a mold cavity by using production grade steel mould material that can make its shot life to be more than 200,000cycles.
Injection Molding Finishes
| Glossy | Semi-Glossy | Matte | Textured |
| SPI-A2 SPI-A3 |
SPI-B1 SPI-B2 SPI-B3 |
SPI-C1 SPI-C2 SPI-C3 |
MT (Moldtech) VDI (Verein Deutscher Ingenieure) |
Injection Molding Materials
ABS
Acrylonitrile Butadiene Styrene (ABS) is a thermoplastic that is created using emulsion.With its Strong, flexible, low mold shrinkage (tight tolerances), chemical resistance, electroplating capability, naturally opaque, low/medium cost.
Common applications:Automotive (consoles, panels, trim, vents), boxes, gauges, housings and toys.
Acetal/POM (Delrin)
POM is a low-friction, lightweight thermoplastic that is strong and rigid with excellent fatigue resistance, excellent creep resistance, chemical resistance and moisture resistance in naturally opaque white with low/medium cost.
Common applications: Bearings, cams, gears, handles, rollers, rotors, slide guides, valves
PC(Polycarbonate)
PC is very tough with temperature resistance and dimensional stability, can be made transparent but in high cost.
Common applications:Automotive (panels, lenses, consoles), bottles, containers, housings, light covers, reflectors, safety helmets and shields
PC+ Glass-Filled
Glass-filled Polycarbonate is a strong and tough material ideal for many industrial applications.
Common applications: Pulleys, medical devices
PMMA(Acrylic)
PMMA is a transparent polymer with good tensile, scratch resistant, can be transparent and optical clarity in low/medium cost
Common applications:display stands, knobs, lenses, light housings, panels, reflectors, signs, shelves, trays
PP(Polypropylene)
PP is in lightweight with heat resistance, high chemical resistance, scratch resistance and natural waxy appearance that is tough and stiff in low cost.
Common applications: Automotive (bumpers, covers, trim), bottles, caps, crates, handles, housings
PP++ Glass-Filled
Glass Filled PP Compound is manufactured by compounding Polypropylene Homo-Polymer with fine grade of Glass, with suitable grade of processing Aid, Heat stabilizer and Anti-oxidant.
Common applications: housings handles, enclosures
PE(Polyethylene)
PE has a low melting point, high ductility, high impact strength, and low friction.
Common applications: Films, bags, electronic insulation, toys.
LDPE(Polyethylene - Low Density)
LDPE is a soft, flexible, tough, and lightweight plastic with good corrosion resistance in natural waxy appearance and low cost
Common applications: Containers, bags, tubing, kitchenware, housings, covers
HDPE(Polyethylene - High Density)
HDPE is tough and stiff with excellent chemical resistance, high tensile strength, high impact resistance and a high melting point.
Common applications: Chair seats, housings, covers, containers and caps
Nylon - Glass Filled & 6/6
Nylon 6/6 has high mechanical strength and rigidity with fatigue resistance, chemical resistance in low creep and low friction with medium/high cost
Common applications: handles, levers, small housings, zip ties&gears, bushings
Nylon - Glass Filled is much stiffer and has better tensile strength than standard Nylon. It also has a low coefficient of friction and high thermal resistance.
Common applications: Bearings, washers, a lightweight substitute for metals where appropriate
ASA(Acrylonitrile Styrene Acrylate)
ASA is an ABS alternative with improved weather resistance.
Common applications: Automotive parts Enclosures, large panels
HIPS(High Impact Polystyrene)
HIPS is easy to mold, recycle, and has high impact strength and stiffness.
Common applications: Packing, dishware, displays
GPPS(Polystyrene - General purpose)
GPPS is brittle, transparent but in low cost.
Common applications: Cosmetics packaging, pens
PBT(Polybutylene Terephthalate)
PBT is similar to PET plastic and a member of the polyester family. PBT is better suited to lower molding and use temperatures. It has high heat and chemical resistance.
Common applications: Automotive (filters, handles, pumps), bearings, cams, electrical components (connectors, sensors), gears, housings, rollers, switches
PBT+Glass Filled
Glass-filled PBT is much stiffer and has greater tensile strength than standard PBT. It also has high heat and chemical resistance.
Common applications: automotive applications, Fire-retardant applications
PET(Polyethylene terephthalate)
PET is the most common material for plastic bottles of water and other drinks. It is also commonly known as polyester and is used to make synthetic fibers.
Common applications: Plastic water bottles, packaging
PC/ABS
PC/ABS is a blend of polycarbonate and ABS that is to get the best properties of both base materials—heat resistance and flexibility. This blend is also more easily processed during injection molding than either of the base materials.
Common applications: Enclosures, large panels;
PVC(Polyvinyl Chloride)
PVC has high hardness, mechanical and electrical insulation properties. It is chemically resistant to many liquids.
Common applications: Medical containers, construction components, piping, cables
PEI(ULTEM)
PEI is a amber color plastic with high temperature resistance and very high dielectric strength, making it great for medical instrument components and electrical insulation parts.
Common applications: Electrical components (connectors, boards, switches), covers, Medical instrument components
PEEK(Polyetheretherketone)
PEEK has high temperature, chemical, and radiation resistance with low moisture absorption.
Common applications:Aircraft components, electrical connectors, pump impellers, seals
PPS(Polyphenylene Sulfide)
PPS has a very high strength and heat resistance with good flow and dimensional stability.
Common applications: fuel system components, guides, switches, electrical insulation, membranes, packaging
PPO(Polyphenylene Oxide)
PPO has great dimensional stability and good electrical properties with low water absorption and high cost
Common applications: Automotive (housings, panels), electrical components, housings, plumbing components
PPA(Polyphthalamide)
PPA is comparable to nylon with higher stiffness, strength, and thermal properties. It has good creep resistance and dimensional stability.
Common applications: Automotive, oil and gas, plumbing components
SAN (Styrene Acrylonitrile)
SAN(AS ) is the Polystyrene alternative with higher thermal and chemical resistance and is hydrolytically stable.
Common applications: Housewares, knobs, syringes
TPE(Thermoplastic Elastomer)
TPE has the look and feel of a rubber-like material but is a thermoplastic that can be re-melted. TPE has good thermal properties and stability at a wide range of temperatures that can be made in different hardness.
Common applications: Automotive applications, household appliances
TPU(Thermoplastic polyurethane)
TPU is is an elastic material with good resistance to oil, grease, and abrasion.
Common applications: Medical device applications, mobile electronic devices
TPV(Thermoplastic Vulcanizates)
TPV is part of the TPE material family. It has the closest in properties to EPDM rubber and has high-temperature resistance and excellent elastisity.
Common applications: Automotive applications, household appliances, sealing applications
PS:We can also source custom materials upon request to meet your product exact application
Secondary Operations After Injection
Pad Printing
Pad printing is a printing process that can transfer a 2D image/logo/text onto a 3D surface.
Water Transfer Printing
It is also known as immersion printing, water transfer imaging, hydro dipping, which is a method of applying printed designs to 3D surfaces.
Painting
Glossy and matte various color painting are both available to be applied on.
Electroplating
It is a process for producing a metal coating on a solid substrate through the reduction of cations of that metal by means of a direct electric current.
Ultrasonic Plastic Welding
It is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld.
Injection Molding Solutions
Rapid Injection Molds:
Ideal for part design validation, request prototype or small volume production.
√ Quick lead time
√ No MOQ request
√ Complex design accepted
Mass Production Injection Mold
Ideal for bigger volume production parts, tooling cost are higher than rapid injection molds but result in a lower part unit price.
√ Up to 500,000 cycles of mold shot life
√ Production grade steel tooling&multi-cavity tooling
√ Can be used for automatic injection process
Injection Molding Case Study
