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
FAQs
1. What is custom plastic injection molding?
Custom plastic injection molding is a manufacturing process used to produce plastic parts designed to meet specific customer requirements. Parts are molded using custom tooling and materials selected based on performance, durability, and application needs.
2. Does custom plastic injection molding support precision parts?
Yes. Custom plastic injection molding can support precision parts that require tight tolerances and consistent repeatability. Achievable precision depends on part design, material selection, tooling quality, and controlled manufacturing processes.
3. What tolerances can be achieved with custom injection molding?
Tolerances in custom plastic injection molding vary based on part geometry, material properties, and tooling design. During the engineering and quoting process, tolerances are evaluated to ensure they align with functional and application requirements.
4. What industries use custom plastic injection molding?
Custom plastic injection molding is used across industries including medical devices, industrial equipment, consumer products, packaging, and specialty applications. These industries rely on molded parts that meet specific functional, regulatory, and performance requirements.
5. How does tooling affect custom plastic injection molding quality?
Tooling is critical to part quality and consistency. Mold design, cooling, venting, and maintenance directly affect dimensional accuracy, surface finish, and repeatability throughout production.
6. What materials are commonly used in custom plastic injection molding?
Custom injection molding supports a wide range of thermoplastics, including polypropylene, polyethylene, polycarbonate, ABS, and engineered resins. Material selection is based on factors such as strength, chemical resistance, dimensional stability, and end-use requirements.
7. Can AdvanTech Plastics assist with design for manufacturability (DFM)?
Yes. AdvanTech Plastics provides design for manufacturability guidance to help optimize part design, material selection, and tooling. Early engineering involvement can improve quality, reduce costs, and support efficient production.
8. How is consistency maintained in custom plastic injection molding?
Consistency is maintained through controlled processes, validated tooling, documented production parameters, and trained personnel. These controls help ensure repeatable part quality across production runs.
9. Can custom plastic injection molding support both prototype and high-volume production?
Yes. Custom plastic injection molding can support prototype, low-volume, and high-volume production. Processes are developed to maintain quality and consistency as production volumes scale.
10. Does AdvanTech Plastics offer secondary operations and assembly?
Yes. AdvanTech Plastics supports secondary operations such as assembly, inspection, and packaging when required, helping deliver finished components ready for customer applications.
