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Custom Plastic Injection Molding

Custom Plastic Injection Molding

AdvanTech Plastics offers custom injection molding services from a variety of plastics from low to high-volume production of a broad range of molded components.

Custom Injection Molding

Injection molding involves the high-pressure injection of melted plastics and resins into custom molds. These molds are typically made of steel and may have cooling or heating lines running throughout the mold to facilitate more precise temperature control. The plastic resin (in pellet form) is loaded into the presses’ barrel via overhead material handling lines or via vacuum tubes from a hopper/gaylord. The pellets are melted in the barrel, and then injected into the mold’s runner system where the melted resin travels into cavities in the mold. Once the material has cooled to a solid, the part is ejected from the mold with the assistance of ejector pins.

Custom Injection Molding Materials

The injection molding process may be customized to accommodate the various melting points of different materials. This process is designed to accommodate a variety of plastic types, including the following.

  • Acrylonitrile Butadiene Styrene (ABS). ABS is a copolymer thermoplastic that creates a flexible and lightweight material. ABS is suitable for products that do not require chemical, electrical, or UV resistance. The molding process can be modified to alter impact resistance, durability, and heat resistance of ABS. ABS may be found in everyday objects such as LEGO blocks, drain-pipes, household appliances and luggage.
  • Low-Density and High-Density Polyethylene (LDPE and HDPE). Polyethylene is one of the most versatile thermoplastics. LDPE and HDPE variations vary in properties such as melting point and flexibility. Both have high tensile strength, impact resistance, and moisture resistance. One key advantage of polyethylene is its recyclability. Polyethylene can be found in plastic bags, films, and bottles.
  • Polycarbonate (PC). PC is an extremely strong, yet lightweight material. PC is transparent and is typically used as a more durable alternative to glass. PC is extremely resistant to impact and can withstand extensive pressure without breaking or cracking. Due to its durability, PC is used in bullet-proof glass, greenhouses, digital disks, eyeglass lenses, and cell-phone screens.
  • Polyamide (Nylon). Nylon has excellent electrical properties as well as chemical and wear resistance. Nylon is used in many industries including in the preparation of medical supplies and sports equipment.
  • High Impact Polystyrene (HIPS). HIPS offers an alternative to styrene. Modifying crystal styrene with rubber customizes the durability of the material. Adding rubber also decreases the brittle nature of styrene. HIPS is highly flammable, but there are flame-retardant and high-gloss grades of HIPS that are used for custom injection molding. HIPS is non-toxic and may be used as a food-grade polymer.
  • Polypropylene (PP). PP is a very robust plastic with a high melting point, good stress resistance, high impact strength, and broad chemical resistance. It is non-toxic and can be used as a food-grade polymer. Polypropylene may be found in kitchen utensils, rugs and athletic clothes.

Machines Used for Customized Injection Molding

At AdvanTech, our injection molding machine capacities range from 55 to 400 tons, with injection sizes ranging from 1.6 to 45.6 ounces. We source all our equipment from well-respected brands such as:

  • ENGEL – Vertical
  • Cincinnati
  • Toyo
  • Husky
  • Toshiba
  • Husky Hylectric
  • Nissei

Value-Added Services

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Custom Injection Molding Materials

AdvanTech’s expert team is prepared to manage your project from design and prototyping into final production. Our experts will ensure that the products you receive fulfill your exact need for custom-molded plastic parts. We accept all 3D/CAD formats including:

  • SolidWorks
  • IGED
  • STP

We also offer a variety of secondary services to minimize your need for additional vendors. Some of these include:

  • Assembly
  • Sonic welding
  • Pad printing for customized parts and brand identity
  • Packaging and shipping of final parts

Custom Plastic Injection Molding From AdvanTech

Custom plastic injection molding can facilitate the production of a variety of plastic products. AdvanTech offers custom injection molding expertly tailored to a broad range of needs across industries. For more information, contact us today.

Injection Molding Materials

AdvanTech Plastics prides itself on the timely and cost-effective design and production of injection molded medical components. Highly trained professionals utilize leading-edge technology to ensure each is manufactured to the exacting standards and tolerances. Some items are:

  • Tracheotomy arbutrators
  • Nasal syringes
  • Dental devices
  • Specimen containers
  • Pharmaceutical packaging

Plastic Injetion Molding

Plastic injection molding utilizes the high-pressure injection of melted plastics or resins into custom-designed molds to produce solid plastic parts and components. This highly versatile method is used for the production of a variety of products made from a broad selection of plastic materials compounds.

Compared to other plastic manufacturing processes, plastic injection molding offers several advantages, including higher precision parts and the facilitation of more cost-effective high-volume runs.

The following article provides an overview of plastic injection molding, including outlining the steps of the process, common plastics and resins employed, key considerations, and how to select the right injection molding partner.

Overview of the Plastic Injection Molding Process

The majority of plastic injection molding operations include the following steps:

  1. The part designer/engineer or project manager chooses a material that demonstrates the proper performance and production characteristics for the desired part or component.
  2. The molding operator feeds the selected compound into a barrel heater that contains a reciprocating screw and heated runners to melt and direct the material.
  3. The reciprocating screw and/or runners heat the plastic or resin into a melted liquid state, and the screw moves the melted material down the barrel toward the injector nozzle.
  4. The nozzle injects the material at high speeds into a steel or aluminum mold in the shape of the desired part or component. The injector pressure and timing ensures that all sections of the mold are filled.
  5. The injected material cools into the shape of the mold and then ejects the solid part from the mold manually or through the use of ejector pins.

All of the parameters of the injection molding process-including the cycle and injection timing, injection pressure, and cooling time-are determined based on the material and product design.

Common Plastics and Resins for Injection Molding

Plastic injection molding is a highly versatile process that accommodates a wide range of plastics and resins, including:

  • Acetal. Acetal-also known as polyoxymethylene (POM)-is a durable and dimensionally stable thermoplastic with excellent chemical, creep, and wear resistance. It is often used for the manufacture of contacting parts such as belt buckles and engineering components such as bearings and bushings.
  • Acrylic. Acrylic-also referred to as poly methyl methacrylate (PMMA)-is a transparent and rigid plastic valued for its light transmission and weathering properties. Typical applications include use as a more durable alternative to glass in pictures frames, car windows, and eyeglasses.
  • Acrylonitrile butadiene styrene (ABS). ABS is a strong and rigid thermoplastic that offers excellent moldability and glossy, colorfast surface finishes. It is suitable for the manufacture of a wide range of products that do not require high chemical, electrical, or UV resistance, such as indoor appliances, children’s toys, and luggage.
  • High-impact polystyrene (HIPS). Polystyrene is a low-cost plastic that is highly machinable and customizable and demonstrates good impact resistance and dimensional stability. As it readily accommodates printing, gluing, bonding, and decorating, it is often used in printing and other graphical arts applications, such as posters, signs, and displays.
  • Low-density and high-density polyethylene (LDPE/HDPE). LDPE and HDPE are polyethylene variations. LDPE offers greater flexibility and a lower melting point, while HDPE provides greater rigidity and a higher melting point. Both materials are used for the manufacture of a variety of products, ranging from packaging to toys.
  • Nylon. Nylon-also known as polyamide-is a highly durable plastic material with excellent chemical, temperature, and abrasion resistance. It is easily combined with other chemicals to enhance certain features for use in a wide range of industrial and consumer products.
  • Polycarbonate (PC). Polycarbonate is a strong and lightweight plastic that can be used as a more durable alternative to glass and acrylic. It is useful for products that require the same clarity with greater strength, such as medical equipment, CDs, light fixtures, and greenhouse windows.
  • Polypropylene (PP). PP is a widely used thermoplastic valued for its durability, elasticity, transmissivity, and insulating properties. It is often used in household and medical components.
  • Polyvinyl chloride (PVC). PVC is a widely used thermoplastic with great tensile strength, high chemical and heat resistance, and durability. Its waterproof nature makes it particularly useful for pipes and plumbing fixtures. PVC blends easily with other plastics and is often compounded with other plastics to enhance its strength and impact resistance.
  • Polyether ether ketone (PEEK). PEEK is a high-performance thermoplastic that is strong, durable, and highly tolerant of gamma radiation and sterilization processes. These qualities make it suitable for use in sensitive products, such as those found in the medical and aerospace industries.

Is Plastic Injection Molding Right for My Project?

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Is Plastic Injection Molding Right For My Project

When deciding whether the injection molding process is right for your project, it is important to consider the overall production costs and whether the total fits within your project budget. Some of the factors that may influence the cost of production are:

  • Size and material of the final product
  • Part design geometry
  • Mold material
  • Estimated production quantity

Once you have determined the above parameters, you can extrapolate the final cost. In general, plastic injection molding serves as a cost-effective method of manufacturing parts in high volumes.

How to Select the Right Plastic Injection Molding Partner

After you’ve decided to use injection molding for the production of your component, it is essential to partner with an injection molding company that fully meets your part and production needs.

Some of the qualities to keep in mind when sourcing and selecting a partner are:

  • Professional experience. Choosing an injection molding partner with a high level of experience is critical. Additionally, an experienced partner can save your company money by optimizing production to reduce lead times, overstocked inventory, and part errors.
  • Company location. A partner located nearby your facility can be easier to communicate with and offer faster turnaround and lower shipping costs. Keep in mind that a rail served location can result in lower transportation and material costs.
  • Sourcing partnerships. Companies with sourcing connections often come with easy access to higher quality molding materials and equipment. This quality can result in faster production operations and better quality products.
  • Facility capabilities. Partnering with a company that meets all of your needs allows you to streamline your operations, saving you time and money. Additionally, they should be able to help you throughout the entire production process, from part design to final delivery.

Why Partner with AdvanTech for Your Plastic Injection Molding Needs?

At AdvanTech Plastics, we offer full-service injection molding solutions. Our experts assist and guide you through every stage of your project-from initial part design through prototyping and full-scale production-to ensure you receive high-quality products that meet your exact needs.

We provide a broad selection of services, including design consultation, project management, prototyping, injection molding production, and secondary part finishing. In addition, our customers can leverage the following value-added services:

  • Assembly
  • Packaging
  • Pad printing
  • Sonic welding
  • Sterilization sourcing

Superior Plastic Injection Molding Solutions From AdvanTech

AdvanTech Plastics is an ISO 9001:2015 & ISO 13485:2016 certified company that offers end-to-end molded plastic product solutions for a diverse set of industries, including medical and dental, beverage and electronic. Our expert team has the knowledge and skills to meet all of your plastic injection molding needs. For more information on our plastic injection molding services, contact our team today.