Injection Molding Services USA

Looking for fast, affordable plastic injection molding services USA? Our team is here to help you take your project from idea to market as fast as possible. Get a FREE quote today.

What is Plastic Injection Molding?

Injection molding is the most cost-effective way to manufacture plastic parts at scale. The plastic injection molding process involves pouring molten plastic into a custom-made mold. Once it’s hardened, you have your plastic part.

It’s the ideal way to produce high volumes of virtually identical plastic parts. Tolerances are small, repeatability is high, and costs are low thanks to using a single mold for thousands of parts.

Injection molding is also extremely versatile. It boasts a wide variety of materials, surface finishes, and colors.

 
Plastic Injection Molding - Kemal Precision Manufacturing

Plastic Injection Molding Services We Offer

Kemal Precision Manufacturing provides fast, precise custom injection molding services USA. Our expert team and advanced injection molding machines will help you take your plastic part design from concept to reality. We offer:

Plastic Injection Molding

We can create precision-manufactured plastic parts to meet your exact requirements. Large, small, complex, simple—whatever you need.

Insert Molding

Insert molding is the process of adding a thermoplastic layer around another part. eg. Adding a plastic handle to a knife or screwdriver. The plastic is often layered over a metal insert.

Overmolding

Also called two-shot molding. This process involves layering two different materials and using a strong chemical bond to strengthen them.

Molds Manufacturing

Our engineers design and manufacture custom molds. Whatever your project and whatever your needs, our top-notch team and advanced machines can match your requirements.

Our Custom Plastic Injection Molding Capabilities

We manufacture a wide range of premium-quality injection-molded parts. And we do so at an affordable price with minimum lead time. Here are our full capabilities:

Part Sizes  From 0.03 x 0.03 x 0.03 inches (minimum) to 70.9 x 47.3 x 19.7 inches (1 x 1 x 1 mm to 1,800 x 1,200 x 500 mm)
Tolerances  +/- 0.003 mm or +/- 0.0001 inches
Repeatability  +/- 0.05mm or +/- 0.002 inches
Machines  Single-cavity, multi-cavity, and family molds. Press tonnage from 50 to 2,800 tons.
Mold Types  Steel & aluminum.
Cycle Times  Service life cycle times of 1,000, 5,000, 30,000, and over 100,000
Mold Classes  105 (prototype testing), 104 (low-volume production), 103 (low-volume production), 102 (mid-volume production), 101 (high-volume production)
Inspection and Certification Options  First Article Inspection, ISO 13485, ISO 9001, and IATF 16949
Materials  Multiple (see list below)
Surface Finishes  20 (see list below)
Value-Added Services  Primary assembly services, ultrasonic welding, post-molding processes, threaded inserts, chrome plating, painting, water transfer printing, hot transfer printing, silk printing, pad printing, engraving, texturing.

Injection Molding Materials

We offer a wide range of raw materials for both tooling and molds. They include:

Tooling Materials
(CNC-Machining)

  • Aluminum: 6061, 5052, 7075 (for prototype injection molding) 
  • Tool Steel: P20, H13, S7, 718, 718H, 738, NAK80, S136, S136H
  • Stainless Steel: 316, 301, 303, 304, 420, NAK80, S136, 316L

Raw Plastic Materials

  • Most Cost-Effective: PP, HDPE, LDPE 
  • Best for Aesthetics: ABS, PC, HIPS 
  • Resistant to Wear & Tear: POM, PEEK, UHMW 
  • Good Chemical-Resistance: PEEK, PP, PBT, PA, PE, LDPE 
  • Most Impact-Resistant: ABS, PMMA, PVC, PE, PC 
  • For Dimensional Stability: PBT, ABS, HIPS, PPS 
  • For a Rubber Feel: TPU, TPE, Silicone 

Additives and Fibers

  • Plasticizers 
  • Flame retardants 
  • Colorants 
  • UV absorbers 
  • Glass fibers 

Injection Molding Surface Finishes

Injection Molding Surface Finishes
Surface Finishing Options

We offer 20 surface finishes to suit your requirements. 

  • Glossy: A shiny, sleek look achieved by diamond buffing. SPI grade A1, A2, and A3. 
  • Semi-Glossy: Uses grit sandpaper to dull the shine a little. SPI grade B1, B2, and B3. 
  • Matte: Grit sanding stones provide a rough texture. SPI grade C1, C2, and C3.
  • Textured: Oxides and dry-blast glass beads give this a coarse surface texture. SPI grade D1, D2, and D3.

Prototype to Production: Our Injection Molding Process

From quotation to delivery, our process is seamless and easy. Here’s how it works.

Our Injection Molding Process - Prototype to Production-min
Our Injection Molding Procedure - Step by Step

1. Get a FREE Quote

It’s easy to request a quote online. Our team will respond within 1 business day with more information on our injection molding services USA.

2. Detailed DFM Report

We’ll provide you with a detailed DFM report including our feedback and advice on your plans. When your part is approved by both yourself and us, we’ll move onto the plastic injection molding process.

3. Mold Flow Analysis & Design

Our mold flow analysis studies how the molten plastic is likely to move through your mold. Once we’re satisfied that mold flow is optimal, we’ll create a precision mold based on your product requirements.

4. Mold Tooling Production

We use top-quality materials in our production tool. This ensures that our final mold is as closely tailored to your specifications as possible. We can do aluminum tooling for market validation before moving into steel tooling for a full-scale production run.

5. T1 Sample Delivery

We’ll send you a T1 prototype to inspect. If you need changes, we’ll go back and adjust the mold at this point. Once you approve the T1 sample, we’ll move into the injection mold production process.

6. Low-Volume Production Process

We create parts in a low-volume custom plastic injection molding process. This maximizes precision and saves you costs in the long run.

7. Quality Assessment

We ensure our parts meet international standards for tolerance and quality. We do rigorous quality control to make sure your parts are always compliant.

8. Rapid Delivery to Your Door

We’ll package your parts meticulously to ensure their safety. Our trusted logistics partners will deliver them to your door, doing everything that can to adhere to on-time delivery.

Why Choose Our Injection Molding Services USA?

Our team has over 2 decades of custom plastic injection molding experience. We’ve created thousands of custom injection molds for thousands of customers. That means we’ve honed our craft over the years. 

Plastic molding manufacturers like Kemal use factories in China. This allows us to produce a wide range of high-quality parts with unbelievable precision and speed, getting your parts to you as soon as possible. 

  • 20+ Years of Injection Molding Experience. Our product developers and engineers have many years of experience in the industry. This kind of expertise ensures that your products are error-free and only handled by professionals. 
  • Consistency and Quality. We use automated inspections to check parts for dimensional accuracy and consistent quality. Your parts will be as accurate as it’s possible to be. 
  • High Capacity. We fulfill both high-volume and low-volume orders. We’re equipped to handle a high manufacturing capacity, providing diverse services in as short a time as possible. 
  • No Minimum Order Quantity. With our no-MOQ policy, we offer injection molding services USA to everyone, regardless of the scope of the project. 
  • Fast, Easy Online Quote Experience. Get a FREE quote online. Plus you’ll receive design advice from our experts before going ahead with the production process.
  • Post-Sale Support & Warranty. We provide exceptional customer service 24/7 and a warranty on defects and breakages.

Let's Start A New Project Today

Injection Molding Process FAQs

Injection molding is used in a wide range of industries for its versatility and consistency. Some of the common applications include: 

  • Automotive Industry: Injection molding can produce complex vehicle parts with excellent repeatability. Car dashboards, bumpers, panels, light coverings, and door handles are perfect for injection molding. 
  • Aerospace Industry: Uses injection molding to mass-produce plastic components. Think turbine housings, panels, seats, and other lightweight parts. 
  • Medical Industry: Precision is essential in the medical field. Syringes, thermometer housings, small containers, and drip valves can be repeatedly produced with very little room for error.
  • Consumer Products: Any mass-produced plastic products can be easily manufactured using injection molding. Kitchen accessories, kids’ toys, cellphones, and more… The applications are endless and the injection mold process is cost-effective.

A well-made injection mold can last thousands to millions of cycles before needing repair or replacement. It depends on various factors, including mold quality, SPI rating, and maintenance of the mold.

The time it takes to design and create injection-molded parts depends on the project. Things that influence manufacturing time include: 

  • How complex the design is 
  • The design specifications 
  • How big the part is 
  • What surface finish it uses 
  • The quantity to make 

Complex designs need a longer production process than simple ones. Larger plastic components take longer to make than smaller ones. And high-volume orders will take more time than low-volume orders. Plastic injection molding companies will give you a detailed quote based on your specific needs.

Injection molding varies in production cost depending on the size and quantity of the part, the complexity of the project, the materials, and the surface finishes. We offer competitive pricing and multiple value-added services for your custom plastic parts. Get a FREE quote from us today and let our injection molding services USA take your product from a dream to reality.

Request A Quote

*We respect your confidentiality and all information are protected.