Plastic Injection Molding Services

Injection molding is a unique process of manufacturing products by injecting molten plastic resins in the mold cavity to produce desired products. This process is widely used in the plastic product manufacturing industry for the high-volume production of complex parts with precision. It offers high repeatability, efficiency, and low cost throughout the process.

With the injection molding process, you can typically manufacture products with complex geometrics and tight tolerance consistently. It is consistent with a diverse range of resin materials and colors, offering flexible and fast production.

However, it demands careful operating and handling, such as temperature and pressure setting of molten material, to ensure premium quality and reliability of final products.

If you are new to injection molding, you can learn more about the process through our detailed guide.

Since it is a versatile and advantageous process for many applications, several high-grade industries use it to produce high-quality and durable molded products.

Some of the common industries that leverage injection molding are as follows:

Automotive Industry:Injection molding is the ideal option for the automotive industry as it offers precision for highly-complex parts. The automotive industry uses injection molding to craft specific car parts such as bumpers, grills, dashboards, car panels, and door handles.

Aerospace Industry:It is another common industry that widely utilizes the injection molding for precise parts manufacturing. The process is used explicitly for making lightweight and functional parts. It manufactures aircraft parts, like enclosures, winglets, structural components, turbine housing, and panels.

Medical Industry:Medical industry demands accurate manufacturing of small and high-grade sensitive parts. From complex medical devices to small equipment such as syringes, drip valves, and containers are constantly made with injection molding process for enhanced durability and sensitivity of medical products.

Consumer Product Industry:The injection molding method for manufacturing plastic products is also common in the consumer product industry. It is used for manufacturing kitchen gadgets, toys, household device enclosures, and musical instruments. The process is compatible with thermoplastics and thermoset material; thus, a cost-effective option for the consumer product industry.

It is a process used for manufacturing plastic products. We heat the plastic material to change it into molten and then pour it around the mold. Molten plastic then solidifies and transforms into the required plastic product. It is quite a convenient method for making complex plastic parts that demand high precision and detailing.  

Injection molding is commonly used for mass production as it is a cost-efficient and relatively faster process than other plastic molding methods. Once the mold is set up, it can be reused up to millions of times to produce identical parts with consistency.

It has been widely used in industries aiming to achieve high repeatability and accurate plastic products.

At Kemal, we follow the 6 fundamental steps for injection mold making:

1. Requirements Analysis Planning

In the first step, we understand the client’s requirements and design the blueprints accordingly. We analyze the requirements, such as mold design, material to use, production capacity, and resources, to plan the entire production process.

1. DFM Report Analysis

We provide free detailed DFM reports enabling clients to understand mold design feasibility in the production phase. Design for manufacturability report allows the clients to determine if the final product meets their requirements.

1. Mold Production

After the approval of the DFM report, the next step is mold production. Initially, during mold production, a Tooling Schedule form is provided to them for monitoring the production cycle at any time.

1. Free Sample Testing

The fourth step is the testing phase, where we provide free sample testing to the clients with a detailed report of the production phase. The testing phase allows us to cater to any issues we encounter during production at an early stage.

1. Mass Production

After a successful testing phase and satisfactory client remarks, we began the mass production of plastic molded products. Our expert teams inspect the process comprehensively to ensure the standard quality of products.

1. Inspection and Mold Saving

We conduct a thorough inspection of produced parts to make sure every part is error-free and perfectly functional. For future production, we clean and preserve the molds in a safe environment.

One thing that is closely considered during the injection molding process is tolerance. However, there is no standard tolerance range specified for molded products. It entirely depends on the mold design, geometric complexity, and part size. Here is a typical tolerance range of common molded parts;

There is no MOQ at Kemal. Whether you need a single part or mass production, we accommodate customers on all order quantities. However, pricing may vary on order quantity. It will be cost-effective in case of bulk orders.

The injection molding process cycle depends on the product’s size, design complexity, and specifications. Manufacturing molded parts in advanced injection molding machinery typically take a few seconds to two minutes. However, complex parts take demand longer cycle time than simple parts. Moreover, the required manufacturing time also depends on the complexity of the finishing and assembling process.

The cost of injection molding services is influenced by multiple factors, including materials, mold complexity, production volume, and more. Therefore, it is not possible to provide a fixed price based on a single parameter. Below are some key factors:

1. Mold Cost: The primary cost in injection molding is typically the design and manufacturing of the mold. Complex molds or those with precise requirements may require more time for design and processing, thus increasing the mold cost. Generally, mold costs are a one-time investment but can be spread over a large production volume to lower the per-unit cost.
2. Part Complexity: The complexity of the product design directly impacts the difficulty of the mold and production cycle. Parts with intricate geometries, fine details, and strict tolerance requirements typically result in higher processing costs.
3. Production Volume: Injection molding benefits from economies of scale. When producing in large volumes, the cost per part significantly decreases because the mold and equipment setup costs are spread over more units. Small batch production, on the other hand, has higher unit costs due to the higher setup and mold costs.
4. Material Type: Different plastic materials have vastly different costs. For example, common plastics like polyethylene (PE) and polypropylene (PP) are more affordable, while high-performance materials such as POM, PEEK, or TPU are more expensive, especially when custom formulations are required.
5. Production Cycle and Efficiency: The production cycle time also affects the overall cost. Parts with longer production cycles result in higher equipment and mold usage time, which increases manufacturing costs. Efficient production equipment and optimized processes can reduce cycle times, improve overall efficiency, and lower costs.
6. Post-processing Requirements: If the parts require additional post-processing, such as surface treatments (e.g., painting, electroplating), assembly, or packaging, these additional steps will increase costs.

To receive an accurate quote, you typically need to provide the following detailed information:

• CAD drawings or 3D models of the part
• Material specifications
• Expected production quantity
• Tolerance and surface finish requirements
• Required post-processing steps

Based on this information, we can provide a more precise quote. For small to medium batch production, costs typically range from a few thousand to tens of thousands of dollars. For large-scale production, the total cost may be higher, but the cost per unit typically decreases.

If you have specific project requirements, please contact us directly to get a detailed quote and our injection molding service plan.

For more detailed insights, explore our expert’s comprehensive guide on injection molding costs in the blog post.

There are several types of processes that injection molding solution companies use for a wide range of applications. Here are some common types of injection molding processes;

• Plastic Injection Molding (Cold-shot & Hot-shot)
• Metal Injection Molding
• Overmolding
• Die-Casting Molding
• Insert Molding
• Gas-assisted Molding
• Micro Injection Molding
• Multi-Shot Injection Molding

An injection mold lasts hundreds of cycles to millions without repair and replacement. It mainly depends on the maintenance, cleanliness, SPI rating, and quality of the mold. If the mold is cleaned and stored under favorable conditions, its lifespan will be extended.

At Kemal, we follow a rigorous process for cleaning and preserving molds to ensure longevity and reusability. We store molds under ambient conditions for future production cycles.

To learn more information about your mold lifespan, check out our detailed guide on injection mold lifespan in our article.

Plastic injection molding service is achievable in a suitable manufacturing facility with advanced machinery and expert designers. Injection molding partners in China like Kemal are known for fast production and precision molded parts.

With our own factory, we provide complete injection molding services from mold manufacturing to mass production in one place. For free quotes and rapid prototyping, contact us.