Injection Moulding

Injection Moulding | Plastic Injection Moulding


We provide custom plastic injection moulding for customers worldwide, in a variety of industries. We are the low-cost leader for high-quality injection moulded plastics with a fast turnaround. We have been in the plastic injection moulding business since 2005. Our customers range from first-time inventors all the way up to listed companies. 

Low Cost: We leverage an offshore manufacturing facility with a lower cost structure in order to offer lower pricing than our purely domestic competitors.

High Quality: We are ISO 9001:2008 certified, and our process quality systems ensure that your parts are the highest quality possible for your application.

Quick Turnaround: We offer three different shipping methods, including next day air, to accommodate your timing and budget requirements.
 
Plastic injection moulding is a manufacturing process for producing large quantities of plastic parts. It is typically used when the same part is being created thousands or even millions of times in succession.
We have been a leading plastic injection moulding company since 2006. We have proudly produced plastic injection moulds and plastic parts for companies in the United States, Europe, Australia, Asia and South America. We’ve done custom plastic injection moulding projects for various industries including medical, automotive, sports, hunting/camping, electronics, food/beverage, containers, packaging and more.
 
Our custom moulding process begins with our instant quotation. Our quotation system also provides quotes for CNC machined plastic prototype parts. We provide inexpensive custom moulds and injection mould plastics, and typically charges 30%–50% less than other plastic fabricators.
 
We offer multiple options for types of injection moulds based on their expected production cycles and the warranty they carry. There are various options for our “in-house” injection plastic moulds – those which you own but we run your parts in our factory – and for our “export” moulds – those which we manufacture and ship to you to run your parts in your facility or a facility of your choosing.
 
We use steel to make a plastics mould as opposed to aluminum for several reasons, including durability and the ability to injection plastic mould complex parts. There are also various types of steel used for a mould for plastic. While P-20 is considered the workhorse of the industry, we will also use other steel types depending on the situation and requirements.
Whether you need a company to build moulds for plastic injection and produce your plastic parts, or you’re just looking for an export mould to produce plastic parts in your own facility, with your own plastics for injection moulding, we’re ready to get the job done correctly and quickly.
 
About Injection Moulding

Injection moulding is the most common modern method of manufacturing plastic parts. It is used to create a variety of parts with different shapes and sizes, and it is ideal for producing high volumes of the same plastic part. Injection moulding is widely used for manufacturing a variety of parts, from the smallest medical device component to entire body panels of cars. A manufacturing process for producing plastic parts from both thermoplastic and thermosetting materials, injection moulding can create parts with complex geometries that many other processes cannot.
 
The first step of getting a plastic part injection moulded is to have a computer-aided design (CAD) model of the part produced by a design engineer. The three-dimensional (3D) CAD model then goes to an injection moulding company where a mould maker (or toolmaker) will make the mould (tool) that will be fitted into an injection moulding machine to make the parts.

Moulds are precision-machined usually from steel or aluminum, and can become quite complex depending on the design of the part. Plastic materials shrink at different rates when they cool, so the mould has to be constructed with consideration for the shrinkage rate of the material being used for the parts. In other words, a formula is applied in the construction of the mould to slightly increase the size so that when the plastic shrinkage occurs, the part will be to the dimensional specifications of the CAD model.

The Process

Plastic injection moulding is a manufacturing process where resin in a barrel is heated to a molten state, then shot into a mould to form a part in the shape of the mould. The resin begins as plastic pellets, which are gravity fed into the injection moulding machine through a funnel-shaped hopper. The pellets are fed from the hopper into a heated chamber called the barrel where they are melted, compressed, and injected into the mould’s runner system by a reciprocating screw.

As the granules are slowly moved forward by a screw-type plunger, the melted plastic is forced through a nozzle that seats against the mould sprue bushing, allowing it to enter the mould cavity through a gate and runner system. The injection moulded part remains at a set temperature so the plastic can solidify almost as soon as the mould is filled.The part cools and hardens to the shape of the mould cavity. Then the two halves of the mould (cavity or “A” side and core or “B” side) open up and ejector pins push the part out of the mould where it falls into a bin. Then the mould halves close back together and the process begins again for the next part.

History of Injection Moulding

The plastic injection moulding process is generally dated back to 1868, when John Wesley Hyatt of billiard ball maker Phelan and Collander was searching for a suitable replacement material for the ivory in billiard balls. Hyatt invented a way to inject celluloid into a mould that processed it into a finished form. In 1872 John and his brother Isaiah patented the first injection moulding machine. This machine was relatively simple compared to the complex machines used by today’s injection moulding companies. It consisted of a basic plunger to inject the plastic into a mould through a heated cylinder. The industry was slow to adopt the injection moulding process, eventually beginning to produce plastic items such as collar stays, buttons and hair combs. Not until the 1940s did the concept of injection moulding really grow in popularity because World War II created a huge demand for inexpensive, mass-produced products.

The plastics industry was revolutionized in 1946, when James Hendry built the first screw injection moulding machine with an auger design, replacing Hyatt’s plunger. The auger mixes the injection moulded material in a cylinder and pushes the material forward, injecting it into the mould. This allowed colored plastic, or recycled plastic, to be mixed in with the virgin material before getting injected into the mould.

Today, screw-type injection moulding machines account for 95% of all injection machines. The industry has evolved immensely over the years due to technological advancements and machine automation. It has come from producing combs and buttons, to a multitude of custom injection moulded products for virtually every industry including automotive, medical, construction, consumer, packaging, aerospace and toys.