A deciding benefit of two shot injection molding is the saving on production time. As multiple levels of a product can be added in this process, there is often no need to do secondary assembly of the item. What would have been a complete secondary step in manufacturing with conventional injection molding, can now be done in one combined molding process.

This category necessitates a straightforward mold, often crafted from cost-effective materials like aluminum or 3D-printed materials. Additionally, it requires minimal raw materials and less advanced machinery, resulting in an overall low injection molding cost. However, the cost per unit part tends to be higher in low-volume production scenarios.

Streamlined tool designs contribute to shorter cycle times in the molding process, enhancing production efficiency and reducing manufacturing costs. They also minimize material waste by lowering rejection rates and decreasing scrap material. Additionally, simpler molds are easier to maintain, which prolongs their lifespan and lessens the frequency and costs of repairs and replacements.

As the name suggests, this process makes use of two injection shots instead of just one as in conventional injection molding. A special mold is used in this process that accommodates the requirements of these two shots. The mold and its supporting systems are designed to perform two shots without having to remove the partially finished product in between steps.

Several factors directly impact your costs, and understanding these key elements is crucial for optimizing your project’s financial aspect.

In two shot injection molding, a product is formed by injecting two different materials into the same mold. These materials are not injected simultaneously, but rather in succession. It is, however, done in one manufacturing step in which the product is not ejected from the mold between the two shots.

In contrast, high-volume production often demands molds made from robust materials like steel, incurring a higher initial cost but providing extended tool life and minimizing the cost per unit produced. The selection of mold material, therefore, becomes a strategic decision balancing short-term expenditure with long-term efficiency and cost-effectiveness in injection molding operations.

Injection molding costs are a focal point for plastic product manufacturers utilizing this process. This article delves into the intricacies of injection molding costs, shedding light on various factors that contribute to the overall expense. By unraveling these elements, you can gain valuable insights into optimizing costs for your specific project.

In no instance during this process is the product ever removed, shifted or moved in the mold. The final product is therefore manufactured as accurate as the mold itself, barring any post process imperfections due to elements such as irregular cooling.

Plastic storage containers can be manufactured with this process. Different colours can be added, along with rubbery edges to seal lids, or soft container surfaces to protect contents.

It is really situation-specific to decide which process suits a product better. Two-shot injection molding is usually a more expensive process but provides the designer with higher manufacturing precision and a better mechanical bond.

In contrast, simpler mold designs with fewer complex features result in lower tooling costs, making them a more cost-effective choice, especially for applications where intricate features are not essential. Striking a balance between design requirements and cost considerations is essential in optimizing injection molding expenses.

Complex designs often require intricate molds with finer details, increasing initial tooling expenses. They may also necessitate advanced machinery and tighter tolerances, leading to higher operational costs and longer production times. Complex plastic molded parts often result in increased cycle times due to additional cooling and setting requirements, reducing overall manufacturing efficiency. Furthermore, the potential for defects rises with complexity, leading to higher rates of waste and rework.

Insert molding involves placing pre-formed components or inserts into the mold before injection. This technique allows for the integration of multiple parts into a single molding process, reducing the need for additional assembly steps. Naturally, a single-step process would mean a lower machine run-time and a lower number of repetitions and cycles. Furthermore, you won’t be assembling separately designed parts together as well and that again would save time. By consolidating manufacturing steps, insert molding can lead to time and cost savings.

If you want to produce high-quality machined parts with a sleek appearance, it’s essential to consider some critical factors related to CNC machining.

Larger parts require more material, leading to higher raw material expenses. They also necessitate bigger, more energy-consuming machines with longer cycle times, reducing production efficiency. As part size increases, maintaining precision becomes more challenging, possibly requiring advanced, costlier processes. Additionally, larger parts can produce more waste, especially in the runner system where excess material is generated, further elevating costs.

In some applications, the cosmetic appearance of a part may not be critical to its functionality. Choosing to forego intricate cosmetic details can result in faster production cycles and reduced tooling complexity, ultimately contributing to lower costs. This practice is particularly relevant for parts where aesthetics are secondary to functionality.

Maximizing the lifespan of molds is a cost-effective approach in injection molding. Reusing molds for multiple production runs helps distribute tooling costs across a larger production volume, reducing the per-part cost. Regular maintenance and careful handling of molds can extend their life, providing long-term cost benefits for manufacturers.

To effectively reduce unnecessary features, a thorough design review is essential, focusing on optimizing part geometry for both functionality and manufacturability. This might involve reevaluating the necessity of certain aesthetic elements, consolidating multiple components into a single, more efficient design, or modifying part dimensions to eliminate redundant or non-critical aspects. The goal is to achieve an optimal balance between the part’s functional requirements and the cost-effectiveness of its production.

Knowing about the injection molding cost can help in optimizing the manufacturing process. This is achievable by understanding different factors and elements, and this article discussed everything you need to know about costs in injection molding and how to use it. Looking for a quality-focused injection molding service provider? At RapidDirect, we offer the best at a competitive price.

Products that are manufactured in a two-shot process can look very good while also retaining the structural properties that are required from them. In this process, the load-bearing structural part can be molded in the first step while the finishing touches can be added using a more appealing material in the second step.

Recognizing the fluctuating nature of pricing and the vital role injection molding cost estimates play in projects, we have crafted an illustrative example to help better understand the cost estimation process.

When considering materials to be used for two-shot molding, it is important to take the chemistry into account. Not all materials bond perfectly, but some may form a very strong molecular bond. An adhesion compatibility chart is given below.

When compared to conventional molding and assembly, or even with modern processes such as insert molding, two-shot molding provides very accurate manufacturing. As the semi finished product does not need to be removed from the mold in between steps, there is no chance of material misalignment. If thermal effects are properly controlled through good product design, the final result can truly be as accurate as the mold itself.

Instead of buying a machine, businesses outsource their project to injection molding service providers. So they no longer incur the heavy cost of purchasing the machine but are subject to the service provider’s service cost.

To simplify mold designs, it’s crucial to eliminate unnecessary features, optimize part geometry, and consider using standardized components. Utilizing CAD and CAM tools can help in identifying and removing superfluous elements, ensuring efficient mold design without compromising product quality.

Despite this, the overall manufacturing cost decreases as production scales up. Hence, plastic injection molding is widely considered a cost-effective solution for mass-producing plastic parts, with the price per part decreasing as quantities increase.

Two shot injection molding offers freedom to the designer, as it negates the use of multiple steps in manufacturing. It provides molding manufacturer with many advantages such as lower manufacturing cost, better aesthetics and ergonomics, superior mechanical bonds and lower production times. Many products, such as toys, automotive parts, medical equipment, containers and toiletries can be manufactured using this method.

Two shot injection molding works well here due to the desirable properties of plastic in a water environment. Hard-wearing base areas can be combined with softer seal surfaces.

In cases where adhesion combinations are unknown, an adhesion test needs to be done before two-shot molding can commence. In cases where the inherent bonding ability is not sufficient, undercuts, shoulders or grooves may be added into the design to lock the two components together.

The equipment used in the molding process is unique. The cost of a machine depends on the size and its level of sophistication (often measured in terms of automation), and it ranges from $10000 (small) or less suitable for low-volume injection molding to $200,000 (large) suitable for high-volume injection molding. Medium molding machines ($50,000 or more) can also be tailored for medium-level molding. Also, you need to consider the following types of injection molding machines and how they affect the cost:

The choice of mold material influences both the upfront investment and the overall efficiency of the manufacturing process. Mold materials vary in cost and durability, with aluminum and 3D-printed molds offering lower upfront expenses suitable for low-volume production.

The plastic injection molding industry has come a long way since its beginning. It has grown a lot in terms of its efficiency and cost effectiveness, but also in new and innovative ways to manufacture products. One of these innovative ways is the process of two-shot molding. This process is sometimes known as multi-material injection molding, 2 colour injection molding, 2k injection molding or double-shot injection molding.

More complex molds, characterized by intricate features, undercuts, or intricate geometries, generally involve higher tooling costs due to increased manufacturing complexity. These molds require specialized machining and longer production times, contributing to elevated upfront expenses.

The production volume affects the amount of raw injection molding material required, the sophistication of the injection molding machine, and the injection mold’s strength/durability/other mechanical properties. The volume of production is divided into three major categories:

On the other hand, smaller mold cavities are generally more cost-effective due to reduced material usage and simpler mold construction. The choice of mold cavity size should align with production requirements, as optimizing for the right balance between cavity size and part dimensions can result in cost savings in both material consumption and tooling expenses.

Note: not all parts will require surface finishing or other secondary services. As a result, you should ensure you need such services to increase overall production efficiency and less material wastage.

After the first step, the mold opens and the platen containing the product rotates 180 degrees on a horizontal axis to align with the sprue of the second step. In this step, the first cavity is sealed off from any injection. As the sprue of the second material is now aligned with the runner for the second cavity, the second shot now commences to mold the remainder of the product.

When investigating manufacturing methods for a future product, injection molding professionals will quickly find that overmolding and two-shot molding are very similar processes. In both processes, molding is done in multiple steps, using multiple materials. Both processes have similar benefits as well, such as savings in time and costs on secondary assembly steps. They do, however, have enough differences to give each merit in its respective field.

Surface finishing includes processes such as annealing, sandblasting, powder coating, etc., in which the part is subjected to increase its aesthetic appeal or functionality. They are separate from the injection molding process itself. However, many service providers will give a discount to clients using them for both injection molding and surface finishing. Also, there are secondary services which can be manufacturing processes(e.g., machining and drilling), assembly services (e.g., sonic welding), and decorating (e.g., pad printing), which can increase the injection molding cost.

Larger mold cavities, capable of accommodating higher material volumes and producing more significant parts in each cycle, typically necessitate more substantial and, consequently, costlier molds.

We have several plastic materials chosen using a stringent and streamlined selection process and an engineering team that can provide professional design suggestions and material selection. Our highly sophisticated manufacturing capabilities and network allow us to ensure high-quality molds and plastic parts. Upload your design today and get instant quotes and free DfM analysis at a competitive price.

This approach simplifies the mold design, leading to lower manufacturing costs as complex molds are more expensive to produce. Furthermore, reducing part complexity translates to decreased material usage, offering direct savings. Additionally, simpler designs can shorten the molding cycle, boosting productivity and cutting down on labor and energy expenses. This also results in molds that are less demanding in terms of maintenance. Importantly, such streamlined designs often yield parts with improved structural integrity and consistent quality, reducing the likelihood of defects.

Items such as toothbrushes can be perfectly molded with two-shot molding. A rigid base plastic can be used with a softer rubber second shot for better grip and coloration.

Medical equipment such as bone saws can be manufactured using two-shot molding. Rubber grips are very important in the function of this equipment. Two-shot molded items also improve hygiene as there are fewer crevices where sub-parts interface, as compared to conventionally assembled items.

Plastic electronic products with LED’s incorporated into the design can be effectively produced with two-shot molding. A translucent insert can be molded into the design to spread or colour the LED light.

In general, two-shot injection molding requires a more complicated, and therefore expensive setup. Two-shot molds typically have a rotating platen that holds the semi-finished product. While this is a more complicated mold design, it does provide the process with higher manufacturing precision. As the product does not need to be removed and handled between steps, this eliminates human or machine error.

Selecting specific materials, such as high-performance plastics, often results in increased expenses. However, optimizing designs and manufacturing processes to reduce material wastage can significantly lower overall costs. While incorporating recyclable materials might lead to a modest increase in initial expenses, it paves the way for more sustainable practices and could prove economically beneficial over time.

Part inspection costs can be specialized or standard. On the one hand, standard inspection is an internal process that requires trained personnel to check for part defects (cosmetic or critical) and a quality verification team to identify the probable cause. On the other hand, specialized inspection involves inviting specialized engineers to inspect the product. Thus, specialized certification costs more, and sometimes injection service providers offer the certification at a cost.

This is where two shot injection molding really come to its own. Two-shot molding enables a production line to maufacture more complex products, with less production steps than ever before. Consider the conventional injection molding process: If a certain product was to consist of two different materials, they would have had to be molded seperately, in two different molds, followed by a manual assembly step. In two-shot injection molding, these two constituents are not only molded in one mold setup, but they are also fused together, eliminating the need for any assembly.

Overmolding utilizes a simpler mold setup, but can not provide the same repeatability, precision and process stability as two-shot molding does. The unit is the cost is however usually lower than that of a two-shot operation. Overmolding does provide the designer the ability to mold over a metal substrate (e.g. scissor blades), which makes it ideal for certain applications.

The tooling cost incurred during injection molding depends on the machining process used in making the mold, the material used, mold complexity, and mold cavity size.

This will require a strong injection mold made from steel due to its long life expectancy, many materials, and, if possible, a sophisticated machine. This should increase the injection molding cost. However, the high cost will be distributed among the parts, reducing the cost per part manufactured. It is important to note that there is a higher cost distribution per part in high-volume production than in medium-volume production. As a result, they have a lower cost per part manufactured.

The process of two-shot injection molding can manufacture ergonomically designed products to perfection. Structural plastic can easily be covered or added on using materials that are more suited for human interface. Soft, rubbery material is better equipped for the human hand as it provides better grip and a softer touch.

There are several best practices to minimize injection molding costs without compromising quality. By strategically implementing these practices, businesses can achieve cost-effective production and enhance overall efficiency.

The process starts similar to normal injection molding with the mold closing to form the first cavity. In this initial setting, the runner for the first cavity is aligned with the sprue of the base material, while the runner for the secondary step is sealed off. The first material is then injected and fills the first cavity.

Part packaging costs depend on whether the packaging is consumer-facing (i.e., recognizable and short-span) or more costly shipping packaging. Consumer-facing packaging is suitable for products that are ready to use. However, larger manufacturers can use automatic packaging, which reduces damage and incurs fewer errors.

Determining whether injection molding is expensive isn’t a straightforward answer. While the process proves cost-effective for mass production of plastic parts, the initial setup costs can be substantial due to high machine prices.

Quality injection molded parts and a cost-effective process are achievable by trusting the right injection molding services. At RapidDirect, we offer custom plastic injection molding services to help you make different plastic prototypes or real parts based on your requirements.

Please navigate to our online quotation platform and upload an injection molding CAD file to get a quick quotation. Our quotation process is comprehensive from start to finish and involves configuring different materials, finishes, quantities, etc. Furthermore, we will confirm the DFM analysis of the mold so that you get the most accurate part possible.

While high-performance plastics may offer specific advantages, they often come with a higher price tag. Analyzing the functional requirements of the part and selecting a cost-effective material that meets those needs can lead to substantial cost savings without compromising quality.

A well-designed part can reduce material usage, simplify mold design, and shorten cycle times, all of which lower manufacturing expenses. Optimizing wall thickness, incorporating uniformity, and minimizing undercuts can lead to more efficient production processes and less material waste. Conversely, complex geometries and poor DFM can lead to increased tooling adjustments, higher defect rates, and prolonged production cycles.

Products manufactured using two shot injection molding exhibit great mechanical properties. During the molding process, different levels of the product form a molecular bond given good material selection. This bond is often stronger than conventional molding and assembly, and even stronger than other advanced methods such as over- and insert molding.

The extremely high level of precision needed within the aerospace industry makes CNC machining a suitable manufacturing process for the sector.

The molds used in two-shot molding consist of different tool sets. In a rotating platen setup, the tools share the same core, but not the same cavities. The runners must be designed as such to be shut off during the molding steps in which it is not active.

Two shot molding enables the designer to utilize the best of multiple materials. Engineering plastics may have many good, but vastly different properties. The designer can combine good structural properties of a hard plastic with the soft and appealing nature of a different material to achieve the desired results accurately.