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Plastic Injection Molding Services

Your solution for high-quality, repeatable plastic parts. From rapid prototype tooling to bridge production, we streamline your path to manufacturing at scale.

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A clear transparent automotive light cover made with injection molding

The Injection Molding Process

Injection molding is the most widely used manufacturing process for producing plastic parts. It works by injecting molten material into a custom-made mold, resulting in parts with excellent accuracy and repeatability.

1. Mold Making

We create a high-precision mold (tool) from aluminum or steel using CNC machining and EDM processes based on your part's 3D CAD data.

2. Part Injection

Plastic pellets are melted and injected under high pressure into the mold cavity, where the material cools and solidifies into the final shape.

3. Ejection & Finishing

The mold opens and ejector pins push the cooled part out. The process repeats, enabling the production of thousands of identical parts.

A steel blank for a multi-cavity injection mold

Tooling for Every Need

We provide tooling solutions tailored to your project's volume, budget, and timeline.

  • Prototype Tooling: Made from aluminum, these molds are a fast and cost-effective way to produce hundreds to thousands of parts for functional testing and market validation before committing to expensive production tooling.
  • Bridge Tooling: When you need more parts than prototyping can offer but aren't ready for mass production, bridge tooling (often made from P20 steel) provides a mid-volume solution (5,000 to 50,000 parts).
  • Production Tooling: Made from hardened tool steel, these molds are built for high-volume manufacturing, capable of producing hundreds of thousands or even millions of parts with high precision and longevity.

Advanced Capabilities & Design for Manufacturability (DFM)

Specialized Molding Processes

  • Overmolding: A process where a second layer of material (typically a soft TPE) is molded over an initial rigid substrate. Ideal for adding soft-touch grips to handles or electronic enclosures.
  • Insert Molding: Metal components like threaded inserts, pins, or bushings are placed into the mold before injection. The plastic then forms around them, creating a single, robust part.
  • Liquid Silicone Rubber (LSR) Molding: A thermoset process perfect for creating flexible, durable, and temperature-resistant parts like seals, gaskets, and medical components.

Design for Manufacturability (DFM)

Successful molding starts with good design. We provide expert DFM feedback on every quote to optimize your part for molding, helping to prevent defects and reduce costs. Key considerations include:

  • Draft Angle: A slight taper on vertical walls to ensure the part can be easily ejected from the mold.
  • Uniform Wall Thickness: Helps prevent sink marks, warping, and inconsistent cooling.
  • Undercuts & Parting Lines: Identifying features that may require side-actions or more complex tooling.

Injection Molding FAQ

What is the upfront cost for injection molding?

The primary upfront cost is the creation of the mold (tooling), which can range from a few thousand dollars for a simple prototype tool to tens of thousands for a complex, multi-cavity production tool. However, the cost per part becomes extremely low at higher volumes.

What is a "parting line"?

The parting line is the line on a part where the two halves of the mold (Core and Cavity) meet. A slight witness line may be visible on the final part.

How many parts can I get from a prototype tool?

A typical aluminum prototype tool is durable enough to produce anywhere from 500 to 10,000+ parts, depending on the part geometry and material used. This is often more than enough for initial market entry and testing.