Jackie Lau, Senior Tooling Engineer and Expert of plastic injection molding, experienced in plastic injection molding and tooling for more than 15 years. The founder and Director of Eco Molding & Sositar Mould.
A plastic part can be manufactured in many different ways. If you anticipate a high enough production volume, one of the most cost efficient ways to get the job done should be the plastic injection molding process.
However, there are multiple considerations when you decide on the plastic injection molding quotes process:
Sales Volume
Appropriate Budget
Specific Application
Time Cost
Sales volume
As stated above, the production method is mainly determined by the sales volume. According to experience, if you are going to sell 1,000 or more parts each year according to forecast (on basis of reliable market analysis, not just because someone said he was going to buy one), it will be worthwhile to consider the plastic injection molding process. Though the startup cost can be a bit too high, after the plastic injection mold is created, it will be quite cost effective to produce the parts. We suggest you get a quote and calculate with your own numbers to maximize return on investment.
Appropriate Budget for plastic injection molding quotes
Undoubtedly, even though the return on investment from your forecast sales volume pencils out, you will have to make effective budget for other aspects, such as the plastic injection mold, the early stage production run and marketing expenses, etc. In the circumstances that you are not funded by yourself, you probably need to develop a sound business plan, so as to attract investors. In exactly the same way, the plastic injection molded part producer will not invest sufficient resources in your production project, unless you are able to convince them that your project is promising and will be profitable.
Specific Application
Another critical factor is the specific application of your final product. Although the plastic is a very excellent material that is able to help you save time, money and lives with an improved sterilization performance, it is not always a perfect choice for all projects. For instance, when you require high strength for your part, which is not available with the plastic, or you specifically require an outstanding durability that enables the product to withstand severe conditions for 5 or 6 years, it will not be a wise choice to adopt the plastic injection molding process.
Time Cost
Typically, it will take 4 – 12 weeks of time to build the mold you need for manufacturing of plastic injection molded parts. Factors that influence the time cost usually range from design revisions, communication lag, part complexity, current load of the tool maker, as well as a diversity of unexpected events that may include shipping delay and production part failure, etc. Due to these factors, you need to allow a longer time to get the final parts produced.
Consider Eco Molding
When you are about to kick off a new project, please consider Eco Molding for plastic injection molding quotes. We believe, we are the perfect plastic injection molded part manufacturer who is able to meet your needs for product development, because we offer a lifetime mold guarantee and enjoy 98% customer satisfaction.
With the appearance of engineering grade resin materials, the conversion from metal to plastic was introduced in the 1950s. However, until today a lot of manufacturers are still not familiar with the benefits of the technique.
Now, in the ever changing landscape, many different sophisticated and cost effective plastic materials are being researched and developed, while many industries have come to realize the benefits of replacing metal with plastic when producing parts. As a matter of fact, for most companies which have replaced metal with plastic, they can expect cost savings of up to 25 – 50%.
The plastic molded parts are able to offer a great number of benefits to businesses in any industry, thanks to the plastic material that is as strong and reliable as the metal, while able to be engineered to the same level of tight tolerances.
The Advantages of Plastic over the Metal
Now, as more and more industries have come to realize the benefits to replace metal with plastic, part manufacturers quickly opt for high volume plastic injection molding as their process of choice.
Plastic parts have multiple common advantages over the metal, such as:
Able to offer a higher tensile strength than a diversity of metal materials
In addition to reduced part weight, as well as improved overall part strength and resistance to corrosion, replacing metal with plastic also allows us to consolidate several different metal parts into a single plastic one. Moreover, apart from providing the equal strength and offering the same level of tight tolerances as the metal, fewer secondary operations are required of a plastic part, thus able to save both time and costs.
Actually, it is possible to build a plastic part that possesses higher quality physical and chemical properties than the metal, with the help of specialized design methods.
Applying Plastic Parts for Cost Reduction
As mentioned above, replacing metal with plastic is able to cut costs by up to 25 – 50%, thanks to the following several factors: one single plastic part is able to replace several different metal parts, so subsequent fastener and assembly can therefore be eliminated; it is able to add colors to the plastic melts during production, so the painting or laser marking processes can thus be eliminated.
In addition to cost reduction, the application of the plastic material can also dramatically enhance parts quality. The advantages of plastic part can be optimized in several ways that include:
The plastic materials are able to be reused
Product service life is extended
Design options are more diversified
Secondary processes which are time consuming and costly can be eliminated
We held a discussion on 3D printing vs injection molding. Although the new printing technology has come into existence for quite some time, it has only been about 5 years since the technique becomes known to the public.
During that period of time, the actual capabilities of 3D printing technology has been overshadowed by how the public perceives it. Now, people would like to inquire more about it along with more recognition of it – every industry player seeks to explore the 3D printing technique, with the aim to find an alternative for their future projects, so that they will be able to move on from more conventional methods, such as the injection molding process.
3D Printing VS Injection Molding
Although these 2 processes are similar to each other – both of them are used to produce parts & components from the plastic material, and are able to handle a high level of complexity in geometry – there are significant differences between them too.
Among all the features of 3D printing technology, one of the most attractive one should be the relatively lower costs in the initial stage. On the contrary, the plastic injection molding process requires a much higher initial cost, because it is expensive to create the necessary special dies. Although it might be overwhelming in the beginning, the initial cost can be amortized over the service life of the mold, as well as the duration of the production run. And, in a large volume injection molding project, the initial cost can be amortized over more individual parts, resulting in a relatively lower cost per part.
Apart from the benefits with regard to startup costs,there are a number of limitations that the 3D printing technique has to overcome, especially when in comparison with the plastic injection molding process. The costly and time consuming misprints still tend to be caused by technical and / or software issues. Nowadays, 3D printers are still not commonly seen, the printing process is considerably slower than the injection molding process, and there are also restrictions in the size of 3D printed parts.
Which Method Works the Best for Your Project?
Both of the 2 processes – 3D printing vs injection molding – are able to produce plastic parts with guaranteed high quality and high complexity. To decide which one works better for your future projects, you have consider one of the key factors: the breakeven point.
When we seek to partner with a plastic injection mold maker, there may be a huge startup cost, even for a high volume plastic injection molding order. This is inevitable for the die tooling process, in which the stainless steel is often used for the mold. So, you have to consider the breakeven point — during the production process, whether the initial cost can be amortized far enough to make the plastic injection molding process a more cost effective method than the 3D printing technique. Other considerations include the size and complexity of the part.
When your production volume is lower than 1,500, 3D printing might probably be more cost effective for you project. However, when your volume is higher than that, the plastic injection molding process would be a wiser choice.
Although 3D printing is a very amazing technology, it is only applied to part or product prototyping at the moment, and only able to handle a very limited production volume. Therefore, we would like to encourage the readers of this article to learn more about the injection molding process, which possesses the full capabilities and benefits to handle large-scale production runs.
The production of high quality plastic products can be attributed to several essential elements. We have a dedicated team of plastic injection molding experts at ECO Molding who have a clear idea about how to create high-performing and reliable plastic parts. Like no others, we are a precision plastic component manufacturer who is able to provide high quality plastic products that are complete and ready to be used immediately. In addition, we keep designing and tooling all our parts in house, and meticulously monitor each and every step in the manufacturing process.
In the following text, we are going to share with you our main areas of focus in the injection molding process, which allow us to create the perfect high quality plastic parts for our clients, regardless of how complicated or uncommon the specific requirements are.
Design of Mold
To begin with, the design of a mold is of critical importance to make sure that the plastic injection molding process is able to produce plastic parts in a high volume, and with ideal productivity and uniformity. With the dedicated team of engineers at ECO Molding, who are good at the design of molds that ensure good quality plastic parts in an extremely efficient way, the risk of costly delays and material waste can be effectively eliminated.
We now enjoy more than 15-year experience in the plastic injection molding field, and our expertise allows us the ability and ingenuity required to build customized molds of any types even in the most challenging circumstances. With the application of cutting edge technologies, such as CAD/CAM systems, our engineers work in close collaboration with the client to thoroughly understand the key requirements for each part, including functions, applications, dimensions, its relation with other components and the ability to withstand certain conditions, etc.
Equipped with such expertise, our engineers are then allowed to identify the main design elements that are required to guarantee that the plastic injection molding process will go correctly as expected. To create the perfect bespoke mold for the client, we will take all the elements into consideration, including wall thickness, rib design, boss design, corner transition, weld line, as well as gate/vent arrangement.
After the draft design is finished, we will initiate the design for manufacturability (DFM) analysis, so as to make sure that our design meets the highest possible standard of quality. Upon design finalization, our engineers will start the new mold building and testing process.
Manufacturing of Molds
If there is not an ideal mold, it will not be possible to produce high quality plastic products. Therefore, we pay great attention to our mold making process at ECO Molding. Since mold making is a time consuming process and it has to allow for highest accuracy, this procedure always represents the most substantial investment that a company has to make in its manufacturing process. However, precise tooling always plays a critical role in guaranteeing a successful plastic injection molding project.
ECO Molding is specialized in the creation of high-quality, precise and enduring mold products. We focus our mold making process on several key aspects to make sure that we create the ideal molds that the client needs:
Reliable design and engineering
Mold bases and cavities made from high-quality stainless steel to ensure the desirable performance and service life
Application of the most sophisticated equipment to ensure precise machining
Focus on stringent quality standards and strict tolerances
We are clear that creating a high-quality precision mold is a substantial investment for you, so we will make every effort to ensure maximum return on investment for you, mainly from the following perspectives:
Core Metal– All the molds we have made employ stainless steel as the core metal. Over the past decades, our molds have been proved to be able to withstand long production runs, while still meeting stringent tolerance requirements.
Cavity Quantity– We seek to maximize the no. of cavities in a mold to ensure the optimal level of efficiency.
Mold Base– We carry out cost estimation of the mold base, the part that holds all mold components together, including cavities, inserts and more on basis of its size, as well as the type of steel used, to allow for the desired level of customization.
Core/Cavity Machining– Our molds are tailored for the client through specific arrangement of cores, cavities, ejectors and cooling channels, etc.
Part Complexity– On basis of part complexity, we determine the mold cost by taking the surface finish of the final product, as well as the number of undercuts needed into account.
In order to build a mold, we can reverse the design of an existing part, or construct a mold on basis of the drawing or CAD file that the client provides. With regard to tool making, our team makes use of several different types of equipment that includes EDM, CNC mills, lathes and grinding machine, to build the desired part. Upon mold creation, we are then allow to choose the appropriate resin for production.
Selection of plastic resin
It is also of critical importance to choose the right material for the production of high quality plastic parts, so as to ensure a successful plastic injection molding process. Over the previous decades, the development of polymer technologies has allowed us a wider range of available resins, which leads to an increase in the applications of plastics in various sectors, as well as an improvement in available plastic materials with higher strength and durability. Our manufacturing experts possess the experience of working with a diversity of resin materials for different types of applications.
We work in close collaboration with every client to identify key requirements for the resin, including the desired appearance of the product, e.g. texture, color and transparency, as well as the strength, flexibility, rigidity, chemical & environmental resistance, the regulatory requirements and the service life of the product.
Production & Quality
After the mold is created and the appropriate resin is selected, the production process can finally start. We now have several state-of-the-art presses in our factory, with different capabilities and performance for the client to choose from. On basis of mold dimensions, the number of cavities and the resin selected, our team of experts will select the right machine to use.
Following that, we will perform a trial run to ensure that no defects will occur. Once any defects are found, we will make corresponding corrections; if everything goes correctly as expected, we will go ahead with the production process, throughout which our team will continue to carry out quality monitoring, in an effort to ensure that all products manufactured meet the highest quality standards.
At ECO Molding, our team takes high quality as the first priority and it is our aim to offer the best high quality plastic products at the most competitive price.
In plastic part manufacturing, the injection molding process is very versatile and possesses many advantages when compared with other plastic molding methods. Plastic injection molding is not only simpler and reliable, but also more efficient than others. Now, let’s see what the advantages of plastic injection molding are:
1.Highly Efficient Production
The plastic injection molding process is proved to be the most commonly applied and most efficient way of injection molding, as evidenced by the several solid reasons. When compared with other processes, The advantages of plastic injection molding is really fast, and more efficient and cost effective thanks to its high productivity. Though production speed is dependent on mold complexity and size, it only takes about 15 – 120 seconds between each production cycle.
With such a short interval between production cycles, a larger number of molds are able to be produced in a very limited time period, thus maximizing revenue and profit for the client. We produce parts 24/7 at ECO Molding by using a material requirement planning system (MRPS). Although this system is not able to replace a manufacturing manager with regard to input and experience, it is really helpful in enhancing production efficiency within the production facility, and in return, this will ensure savings for our clients.
2.Complicated Product Design
The injection molding process has the ability to deal with very complicated product designs, while ensuring uniformity, by making hundreds of thousands of virtually the same parts. During the design process, we will take all key elements into consideration, in an effort to optimize the efficiency of injection molding in a large volume, and at the same time maximize part precision and quality for you. First of all, part design has to be developed with the aim of maximizing the effectiveness of large volume plastic injection molding. When design is done right, the part can be produced consistently with high quality. If a good design is not in place, costly mistakes might occur during the process.
Most professionals in the molding industry see eye to eye that the fundamental design elements in the plastic injection molding process have to work correctly, including wall thickness, rib design, boss design, corner transition, weld line, as well as gate/vent arrangement.
3.Enhanced Part Strength
One of the key elements that need to be identified during the design process of a plastic injection molded part is strength. Designers need to have sufficient expertise on whether the desired part is required to be flexible or rigid, so they can make appropriate adjustments to the integrating ribs or gussets. In addition, it is also very important to know how the client is going to use the part, as well as what conditions the part will be exposed to.
It is better to strike a balance between design considerations, because it is able to help address your needs for part strength and stability. Another key role defining the part strength is selection of materials. In the text below, you can find more information on resin types used in the plastic injection molding process.
4.Flexibility in Both Material and Color
Another 2 factors in construction of plastic parts are selections of the right material and the right color for your production project. However, the possibilities are almost infinite thanks to the almost endless variety of material and color. Over the past years, polymers have been developed to allow a wider selection range of resin materials for the client to choose from. It is recommended that you work in collaboration with a plastic injection mold maker who is experienced with a diversity of plastic materials and their particular applications, including those compliant with FDA, RoHS, REACH and NSF. To make sure you choose the most appropriate material for your production, you have to keep the following factors in mind, including impact strength, tensile strength, flexural modulus of elasticity, as well as heat deflection and water absorption
A variety of coloring systems can be used to color the plastic materials, each possessing its unique features, benefits, and weaknesses, among which masterbatches, “salt & pepper” blends, liquid color, and pre-colored plastic are the four most commonly applied coloring methods.
5.Waste Reduction
When you are looking to partner with an injection mold maker who possesses a large volume injection molding capacity, it is of great importance to consider the manufacturers who advocate the Green Manufacturing initiatives, because these can indicate their commitment to product quality, sustainability and great safety. It is inevitable for the plastic injection molding process to generate excess plastic. So, you need to find a mold maker who has put a recycling system in place for the excess plastics. To minimize waste, transportation and packaging, the most environmentally friendly plastic injection mold makers will look to employ cutting edge machinery to achieve the targets.
6.Lower Labor Costs
The plastic injection molding process is typically associated with a lower labor cost when compared with other molding methods, which should be attributed to its ability to produce parts to a high quality standard and with a high output rate.During injection molding, minimal supervision is required, as the molding equipment usually runs with a self-gating and automatic tool to keep production streamlined and ongoing.The advantages of plastic injection molding can reduce the cost a lot on this aspect.
In today’s market, there are tons of resin materials available for the client to choose for plastic injection molding project. So, the selection process for plastic materials often seems very challenging in the very beginning.
At ECO Molding, we are clear that each type of plastic material boasts unique features and benefits, so we work in close collaboration with the client, in a bid to explore the most appropriate plastic material for their production projects.
The following are some most commonly used resin materials for the plastic injection molding process:
ABS
As it boasts a remarkable impact and mechanical strength, the ABS (Acrylonitrile Butadiene Styrene) is applied in a broad range of industries, from automobile to pipe manufacturing. Metal coatings adheres to ABS easily, so the material is a perfect fit for production of such products as telephones, shower heads and handles, etc. However, the material is not very resistant to chemicals, so it is better not to use it in the applications that require electrical insulation or resistance to UV.
Celcon (Acetal)
Celcon, also known as Acetal, boasts outstanding surface lubricity, resistance to creep (memory) and chemical solvents. It is an ideal material for applications in the food, beverage, mechanical, automotive and household industries. We usually choose this resin to manufacture toy components, as well as gears and bearings. Besides, it is often applied in production of automotive and household products. However, it is not a good choice for applications under high temperature conditions.
Polypropylene
Polypropylene, commonly known as PP, is best known for flexibility in the industries including packaging, fluid management & processing, household products and production of some automotive parts. Although polypropylene is a flammable material and susceptible to UV radiation, it still provides good chemical and electricity resistance. The majority grades of polypropylene are flammable and subject to degradation by UV radiation.
HIPS
HIPS, short for High Impact Polystyrene, is a tough material with a low-cost performance and customizable surfaces. This material is able to be easily printed, glued, bonded and decorated, and is commonly seen in such industries as merchandising, displays, printed graphics, as well as prototypes. Though it is flammable, there are flame-retardant varieties available on the market.
LPDE
LPDE, i.e. Low-Density Polyethylene, is the version of polyethylene with the highest flexibility. It boasts a strong resistance to moisture and a high impact strength. The LPDE material is usually used in production of many consumer products, housewares, as well as medical supplies and electronic wires. However, this material is difficult to bond, so it is better not to use it in extreme weather or high-temperature conditions.
Keep the following variables in mind when selecting a resin materials for your production project:
Impact Strength – The production of some parts requires a higher base strength than the rest of them, so the IZOD impact strength of a resin material should be identified from the very beginning.
Tensile Strength – We use ultimate tensile strength or ultimate strength to measure a resin’s tension resistance and its capability to withstand a certain amount of load without falling apart.
Flexural Modulus of Elasticity – This term measures how much a material can be bent without being damaged and is still able to return to the original shape.
Heat Deflection – For production of products that requires insulation or tolerance for a relatively wider range of temperature conditions, the heat deflection performance is of great importance.
Water Absorption – It measures how much liquid is taken by a material after 24 hours of immersion, usually measured in percentage.
Selection of Resin Materials for Custom Applications
If you choose the most appropriate material from the very beginning, you will not only save time and money, but also you will ensure the highest possible level of performance and manufacturability. To identify the ideal material choice, we suggest you research your options in a careful manner while consulting with a qualified plastic injection molding maker.
Let me ask you a question: how frequently do you look for an good injection mold maker? Most firms and project managers would reply “seldom”. The benefit is that once you have decided on an injection mold maker to work with, you will probably stay with it for quite a long period, provided that they are able to produce plastic parts with the desired quality.
In the following scenarios, you may need to look for an injection mold maker:
– A newly designed product of your firm requires injection molding
– An existing injection molded part of your firm has been redesigned by your engineers
– The current injection mold maker can no longer meet your requirements for high quality
– Your manufacturing location has changed
As a result, when you are looking for a new mold maker, how can you make sure that you select the right plastic injection mold maker for the job?
We have collected the FAQs and then offered replies to each of them. If you can review these questions before you visit an injection mold maker, you will probably get the information you need, so as to do a proper assessment.
A: There are several advantages if you partner with an injection mold maker who possesses the in-house capabilities to help carry out your project through from conception to completion.
– During the development process, design refinements are often made in the early stages. If you are able to work with a turnkey mold maker, the refinements can be made and reviewed within a shorter period of time.
– Through dedicated training, designers are able to create the best design for a project. They possess the required expertise to create the molds that will help produce the desired parts in the highest quantity and with the highest quality.
– Look for a plastic injection mold maker that employs the latest technologies in precision CNC and EDM.
Q: What is their product lineup and what are the specs (capabilities)?
A: The mold maker with a larger number of presses is able to cope with more projects within a given period of time, but they also have to have a wider range of machine sizes. The measurement of an injection molding machine is pressure or tonnage. A plastic injection molding machine is able to run from 40 to 4,000 tons. The larger the machine is, the larger mold it is able to accommodate. Yet, not all parts are able to run well on larger size machines. Your mold maker will help you identify the most appropriate machine on basis of the quantity and dimensions of the part, as well as the material selected.
Q: Will they guarantee the mold throughout the life of my project?
A: This question is of critical importance. When you are working in collaboration with the manufacturer who has engineered the mold for you, they should definitely offer guarantees. If you need to make a slight adjustment or repair to the mold, the mold maker should fulfill their due obligation.
It can be a tough task to find an appropriate mold maker for you company from the enormous plastic injection mold makers across the whole world. We have compiled this questions and answers in the hope to help you make a comparison between injection mold makers, so that you can choose the most appropriate one for your future projects.
Different plastic materials are being used to produce different objects in the manufacturing industry nowadays, and the manufacturing of each part needs a unique plastic molding process that can form the part on basis of its specs. Before you produce a plastic product, you need to determine the specific plastic molding process that would best address your production needs. In this article, we offer a general overview on 5 different plastic molding types, their strengths and specific applications.
Blow Molding – applicable for production of hollow items, e.g. bottles
Blow molding is often applied to glass blowing, in which a parison (heated piece of plastic, usually a tube) is air inflated. The plastic material is pushed by air against the mold to get the desired shape. After cooling, the plastic part will be ejected.
This molding process is mainly used to produce one-piece hollow items in a high volume. It is the right process for you to make a lot of plastic bottles. The blow molding process is able to create thin-walled containers in a very consistent and yet economical way.
Compression Molding – applicable for production of larger items, e.g. automotive spare parts
As its name indicates, in this molding process, the heated plastic material will be placed in a heated mold, which will compress it into the desired shape. Though often coming in sheets, the plastic material can also be in bulk. The integrity of the final product is maintained by curing (heating). Like other molding processes, after the part is shaped, it will be ejected. In the circumstance where plastic sheets are used, the plastic material needs to be trimmed in the mold before part removal.
Compression molding is designed to deal with high-strength compounds, e.g. thermosetting resins, fiberglass and reinforced plastic materials. In the compression molding process, the application of the materials with outstanding strength properties makes it the most appropriate process for the production of auto parts.
Extrusion Molding – applicable for production of long hollow objects, such as tubes, pipes and straws
Different from other plastic molding types which get the plastic materials into a mold through extrusion, extrusion molding, as its name indicates, extrudes the molten plastic into a die, instead of a mold, to determine the shape of the final product.
The extrusion molding process forces the molten plastic material through a die to get the desired shapes with a fixed section. Many different shapes can be obtained through this process efficiently. Due to the fact that the plastic material needs to be melted and then solidified, only thermoplastics is strong enough to undergo the extrusion process. After cooling, the final extruded part can be cut or rolled for easier shipment.
Injection Molding – applicable for production of high-quality, high-volume parts
Among all plastic molding types, injection molding by far serves the most versatile purposes. Rated on basis of tonnage or pressure, the presses applied in the process differ in size, among which, the larger ones can be used for production of auto parts, while the smaller ones can be applied to produce very precise parts, such as those for surgical purposes. Besides, a lot of different plastics and additives can be used to increase the flexibility of injection molding for designers and engineers.
With regard to the process itself, it is very straightforward, but a lot of enhancements and customization technologies are added for production of parts with the desired surface finish and structure. The injection molds are generally made from steel and designed with cavities to form the part. During this process, molten plastic is injected into the mold, and filled into mold cavities. After cooling, the part will be ejected by ejector pins.
In this method, the cost of the mold itself is relatively high, but the cost of every part is rather low. Cost effective part, diversified resin and finish options have made the injection molding process a popular technique in the present manufacturing industry.
Rotational Molding (AKA Rotomolding) – applicable for production of large, hollow, one-piece items
Rotational molding coats the mold interior to form the desired part by using high temperatures and rotational movements. In this process, the mold rotates constantly to create the centrifugal force that is used to form even-walled parts. Though not a very fast moving process, it is an ideal method for manufacturing of large hollow containers, e.g. tanks. In addition, it is a more cost effective way for production of particular parts, when compared with other molding types. In this very process, little material is wasted and excess material can be recycled, making it not only economical, but also environmentally friendly.
Every plastic molding types has its unique advantages and disadvantages. Designers and engineers need to keep these differences and options in mind when planning for the most appropriate plastic molding types. Mold makers should be able to provide more in-depth insights into what best fits a particular project, be it applications or materials.
To some extent, it is a lot to ask how much a plastic injection mold costs. It is a like asking “How much does your car cost?” Will your mold be a Toyota or a Bentley?
The factors that determine the cost you pay for a mold are a combination of several elements, including part dimensions, complexity, selected materials and required quantities. For example, if you need 1,000 simple parts every year, we will recommend a single-cavity mold to you, i.e. it produces one part in each cycle. In this case, the mold will probably cost you 1,000 – 2,000 USD.
Another example: if you need 1,000,000 remote controllers per month, we will create a 16-cavity mold for you, which makes 8 covers and 8 bottoms in every cycle. In this case, however, you will need to pay 4,000 – 10,000 USD or more.
Surely, the 2 examples mentioned above are every extreme, but it gives us a general idea about how much a mold would cost you, and your specific part will probably fall somewhere in between.
In addition, the selection of material is another factor that determines how much a plastic injection mold may cost. For example, if you require a fiberglass filled product, you will probably need a mold that is made from hardened tool steel, so as to cope with the wear such materials might cause during the injection molding process under high pressure conditions.
It will be useful to tell your mold manufacturer if you already have a target price in mind for your parts. When they design the mold, they can keep your target price in mind, and then make appropriate planning to achieve your desired price with expertise. Although you do not need to know all the details about the available molds, it is better that you come prepared. If you are able to offer the basic information to the mold maker, it will be helpful for them to create the most appropriate mold for your production project. We also recommend that you look for a mold manufacturer who also possesses production capability. A company that is responsible for the production will not create a substandard mold, since they have to reply on it for production activities.
No matter what your project needs, One thing ECO Molding would not do is to suggest you invest in a Porsche when all you need is a VW.
Plastic refers to the numerous organic synthetic materials that are mostly polymers of high molecular weight. Currently, it is one of the 3 synthetic materials that are indispensable for our day-to-day life, while the other 2 are synthetic rubber and synthetic fiber. Natural or synthetic resin, the main ingredient of plastic, is often mixed with a variety of additives, so that the material can be molded into desired shapes under certain temperature and pressure conditions, and maintain the shape at room temperature. As a high molecular compound, plastic molding can be processed with various methods, each of which is a blend of pros and cons, and suitable for specific applications. Now, let’s see how plastic is molded through some relevant interesting animations.
Injection Molding
Injection molding is a parts manufacturing process by injecting plastic molding material into a mold, of which the main method applied is injection molding. In this process, the plastic is loaded into a hopper, which will then feed the plastic into a heated injection unit. After being pushed through a long chamber with a reciprocating screw, the plastic material is melted into fluid. An injection nozzle is located at the end of the chamber, through which molten plastic is forced into a cold, closed mold. After the plastic is cooled and solidified, the semi-finished product will be ejected from the mold.
Plastic Extrusion
Plastic extrusion is a process for massive production, in which the plastic material is melted into a continuous shape. The extrusion process is usually applied to produce films, continuous sheets, pipes, profiles, bars, coating wires, filaments, cords and cables, etc. Together with the injection molding machine, the dried plastic material is loaded into a hopper and fed into a long heating chamber. At the end of the chamber, the material is forced out from a small opening or into a mold that’s in the shape of the desired product. As the plastic leaves the mold, it will be cooled down on a conveyor belt. A blower is sometimes involved in this process to facilitate cooling.
Blow Molding
Blow molding process is applied to produce hollowed plastic products. Making use of air pressure, this post-forming technology blows the rubbery state parison in a closed cavity into a hollowed product.
Thermoforming
Thermoforming is a special manufacturing process which shapes the thermoplastic material into various products. The plastic sheet fixed on a frame is heated, softened, and then pressed against the molding surface under an external force, so as to mold it into the desired shape. After being cooled and trimmed, the desired product is obtained. This process is also applicable to rubber manufacturing. In recent years, thermoforming has witnessed all-new progress, e.g. the continuous production technology from sheet extrusion to thermoforming.
The 2nd animation shows the thermoforming process that involves 2 plastic sheets.
Compression Molding
Compression molding is the most commonly applied process for thermosetting materials. Usually, it is not applied to thermoplastics. In this process, the material is compressed into the desired shape. Plastic molding powder and other additives are added into the mixture to create special properties. When the mold is closed and heated, the material will be hardened to form the desired shape. The appropriate temperature, pressure and time duration applied in the process is dependent on the desired result.
Calendering
Calendering is a finishing process of heavy leather. When heated, the plasticity of the fiber is utilized to smoothen textile surface or create fine-grained parallel diagonals on the surface, so as to improve textile glossiness. After feeding, the material is heated and softened, then shaped into a sheet or film, and finally cooled down and rolled up. The most commonly calendered material is PVC.
Pultrusion
Pultrusion refers to the process where the blank is put under an uneven pressure from 3 different directions, and then extruded from mold opening or crevice, so as to reduce the sectional area and increase the length for production of the desired product. This blank forming process is referred to as pultrusion.
Vacuum Forming
Often known as suction forming, vacuum forming is a plastic processing technology by which a hard plastic sheet is vacuum-compressed against the mold surface after being heated and softened. After cooling, the desired product is produced. This process is widely applied in industries like plastic packaging, lighting, advertising, decoration and more.
Rotational Molding
Also known as rotational moulding or rotomolding, the rotational plastic molding process firstly feeds the plastic material into the mold, which will keep rotating along the 2 vertical axes while being heated. Under the influence of both gravity and heat, the plastic inside the mold will gradually and evenly spread over and stick to the entire surface of the mold cavity. After cooling and ejection, the desired product will be made.
