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What is Injection Molding?
Injection molding is the process of injecting molten plastic into a mold cavity, rapidly cooling it, then ejecting the solidified plastic part. It is the most widely used manufacturing process for plastic parts and the most affordable route to mass production. Once the metal mold or tooling has been made, hundreds, thousands, or millions of plastic duplicate parts can be made in a short timeframe, with the effective cost-per-part reducing with each additional molding as the cost of the mold is amortized. Injection molding is compatible with a very wide range of materials — including thermoplastics, thermosets, and even metals — which can be easily mixed with color pigments and other additives to tweak the function and appearance of the moldings. Furthermore, the injection molding process offers excellent consistency between units, as the tooling remains constant throughout.
At 3ERP, we offer a range of injection molding services, from affordable low-volume prototyping to part production, using thermoplastics, thermosets, or metals. Our team of experienced molding specialists can guide you to the right solution, whether you need rapid aluminum tooling for a fast prototype or a more durable solution for larger production runs. Unlike many molding companies, we do not specify a minimum order quantity.
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Our Injection Molding Capabilities
We are always ready for the challenges of all types of injection molding parts, such as tight tolerances, thin wall, small draft angle, undercuts, complex part geometry, non-defect surface finishes, etc.
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We can fabricate injection molding tooling in aluminum — ideal for rapid low-volume prototyping — or tool steel. Molds adhere to SPI mold classification, which specifies the durability of tooling and for how many cycles it is suitable.
Addition Injection Molding Options
How Custom Plastic Injection Molding Works
Injection molding uses an injection molding machine made up of three sections: the injection unit, the clamping unit, and the mold or tooling. Such machines are large, expensive, and require expert operators.
During the injection molding process, plastic material in the form of small pellets or granules is fed into a large hopper. The machine moves the pellets from the hopper to a heated barrel, where they melt down into a liquid. Within the barrel, a reciprocating screw — which functions as a kind of plunger — pushes the molten plastic towards the check valve. When enough material is ready to be injected, high pressures are applied, and the material is forced into the mold through a network of channels called sprues and runners. The plastic solidifies, taking the shape of the mold cavity, and is then ejected from the mold with the aid of ejector pins. The process then repeats, with cycle times ranging from a few seconds to upwards of a minute.
When ordering custom injection molding parts from 3ERP, we will first review your design and send a quotation. When quantities and pricing have been agreed, we will quickly fabricate the tooling and, if required, send a sample molding before starting production.
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Injection Molding Applications
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Injection Molding
FAQ’s
How quickly can you produce parts using injection molding?
The first step in our injection molding service is to design the injection mold tool. How long this takes will depend on the complexity of your project. The usual timeline can be as short as a week and as long as a couple of months.
What is the process behind injection molding?
The plastic pellets are melted and then inserted in liquid form into the mold tool, where it cools and takes the required shape. The process allows for high precision and tight tolerances because it can be replicated exactly each time.
What plastics can you use with injection molding?
Injection molding can use almost any type of plastic that can also be combined together. This unmatched versatility makes injection molding so popular and suitable for some of the most demanding industries in the world. You can check out the selection of available materials and finishes our injection molding service handles on this page.
Why should I use injection molding?
Injection molding is one of the most affordable ways to manufacture large quantities of parts, especially for bigger production runs. Even though design for manufacturing and creating the mold can take time, the process then becomes very affordable and efficient.
Why Use PPS Injection Mold Services?
Why Use PPS Injection Mold Services?
Related Resources
How to avoid injection molding flow lines
How Much Do Injection Molding Costs and How to Estimate It?
Flow Through the Details of China’s Plastic Injection Molding Process
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