Yes. Injection molding can be used to manufacture metal parts, by a process called metal injection molding (MIM), in which metal powder is mixed with plastic and molded. The plastic is subsequently removed, and the remaining part sintered.

We address the most important design concerns for injection molding projects above, in the Important Factors to Consider for Injection Molding section. Below are more helpful guidelines:

Aero-Plastics specializes in injection molding projects such as insert molding and other value-added services. We offer injection molding PEEK, Ultem and other high-performance engineered resins, plus commodity resins such as polypropylene, polyethylene, polystyrene, ABS, and nylons.

A straight-hydraulic injection molding machine uses a hydraulic cylinder to open and close the mold, and then inject plastic through a nozzle in the machine. This type of injection molding machine produces parts with high repeatability and accuracy.

Injection molded products may be better suited for some projects over others, and understanding more about the plastic injection molding process can help you make an informed decision.

After setup costs are paid off, the price per unit of products manufactured via injection modeling drops steeply and remains extremely low. The more parts produced, the lower the individual cost, making plastic injection molding especially suitable for high volume production.

While this material is a popular choice, under certain conditions, polyethylene can warp and suffer environmental stress fractures.

Designs that are well-suited for plastic injection molding should ideally have a uniform wall thickness, as well as avoid sharp corners, undercuts, and other features that could increase manufacturing time or, in some cases, require additional molding processes for an individual injection molded part.

MIM allows us to produce intricate parts in a wide range of metals, including steel, stainless steel, and high-temperature alloys.

Before deciding on injection molding for your manufacturing process, it’s essential to consider a few key factors, including:

This molten plastic is then injected at high pressure into a mold cavity and cooled to form the desired shape. Molds are usually designed by an engineer or industrial designer, who then further refines the mold with precision machining.

Injection mold production requires a significant up-front cost, in order to prepare the mold and manufacturing setup. However, this subsequently ensures a low production cost after that initial investment is paid off.

We want you to achieve the best value possible — so our experts work with you on these tolerance objectives. Over-specified tolerances can increase project costs, and we understand how to minimize them without sacrificing product quality.

Our knowledgeable team can help you determine the best plastic materials and process for your specific application and unique needs.

Injection molding tolerances, listed below, are directly related to the material to be molded; part size and part geometry. We review parts and tolerances on a case-by-case basis during quoting, and use a Design for Manufacture process to align your project goal to our manufacturing methods.

Our team of experts will assess physical factors that can influence tolerances, namely the material being used as well as the size and shape of the part being manufactured.

Aero-Plastics offers injection molding services for a variety of applications including medical, consumer goods, industrial equipment, automotive components and more. We have the capabilities to provide you with a custom solution that meets your needs.

Your project’s level of complexity is what determines the level of “customization” it requires — in other words, the level of engineering and design support required, analysis needed, and number of process technologies required.

Injection molding is a manufacturing method in which molten material – commonly a thermoplastic or polymer – is injected into a mold in order to produce a part.

Polyethylene plastic is the common choice for high-volume, low-cost injection molded applications. It can also be overmolded onto tubing for surface smoothness or roughness. Polyethylene is also used to produce sheeting for food wraps and plastic film. Interested in using this material for your project? Request a quote to get pricing.

Unsure if your part is suited for the injection molding process? Our experienced engineers are happy to answer any questions you have and will work with you to determine if plastic injection molding is right for your project.

Larger parts require a larger tool set and will have greater variation in wall thickness, which can often create an increase in available tolerances.

While cheaper methods make for a quicker time to market, custom injection molding takes more care with part design, material selection, mold design, and process control in order to achieve more consistent and accurate end products.

We use a Design for Manufacture process to align your project goal to our manufacturing methods. This process allows us to evaluate the design of a part and molding process before production begins – which ensures that we can successfully meet your requirements and attain part quality.

Before selecting plastic injection molding as your production method, it’s important to first determine how many parts need to be produced in order to make the process (and initial investment) cost-effective. You may do this by figuring out how many parts it will take to break even on the project, and building in a conservative margin.

The most common polymers and thermoplastics used for injection molding are acrylonitrile butadiene styrene, polyethylene, polycarbonate, polyamide (nylon), high impact polystyrene, and polypropylene.

The molds used for injection molding offer one of the strongest guarantees that parts will match the original. This lends to brand-consistent quality and part reliability and reduces the amount of plastic material waste.

When the part is ejected, it can be post-processed if needed (e.g., painting, finishing) before being shipped out for use.

At Aero-Plastics, we specialize in producing high-quality parts with tight tolerances, thanks to our team of experienced engineers and detail-oriented processes.

The plastic injection molding process begins with the melting of raw material in a heated barrel, used to mix the desired material prior to injection.

At Aero-Plastics, we strive to provide the highest quality plastic injection molding with the following tolerance objectives, which relate directly to the material to be molded.

While injection molding has a significant up-front cost, it quickly turns into one of the most cost-effective methods of manufacturing parts.

The characteristics of plastic injection molded polyethylene differ by the grade selected with HDPE having the greatest strength and rigidity and LDPE showing the most softness and flexibility. Polyethylene is:

High-density polyethylene injection molding results in products that are less flexible and stronger than products produced by injection molded lower-density polyethylene. With the fewest crystalline branches in its makeup, HDPE is defined with a density range of .941 to .960 g/cc. Although it has greater impact resistance, HDPE can sometimes be used in place of polypropylene, another commonly produced plastic found in commodity products.

Within the broad industry of consumer goods, plastic injection molded polyethylene applications using grades from high density to low are found in many products, including:

The more complex a part’s geometry is, the higher the tolerance objective has to be in order to maintain quality and consistency. Complex features with tight tolerances may require substantial design revisions or additional tooling.

As a group, polyethylene plastic is the most widely-used plastic in consumer goods. The range of polyethylene plastic materials is defined by density produced by crystalline branching within the material composition. The material grades include high-density polyethylene (HDPE), medium-density polyethylene plastic (MDPE) and low-density polyethylene (LDPE). Within the low-density polyethylene family, linear low-density polyethylene (LLDPE) is stronger and less flexible than LDPE.

For tight tolerance parts, we can combine molding with post-mold machining operations. We’re on the Boeing QPL for all types and classes of molded parts, and an approved molder on the D1-4426 for BAC 5321 class II injection molded parts.

The clamping unit of injection molding machines is used to open and close a die in the machine, and to eject the final product.

At the other end of the polyethylene spectrum, LDPE has many crystalline branches in its composition for an end product that is softer, more flexible and less brittle than the polyethylene materials with higher density ranges. LDPE and LLDPE are often used for lower temperature injection molding applications and will not withstand the high temperatures tolerated by HDPE.

Simplifying production times often comes down to finding ways that can reduce the number of steps or tooling changes during the injection molding process. This could involve combining parts into a single section or reducing gate locations on the product.

A heated barrel mixes the desired material and injects it into a mold cavity. Through the cooling process, it hardens to the shape of the cavity, creating the desired product. Molds are usually designed by an engineer or industrial designer, who then further refines the mold with precision machining.

Manufacturers typically turn to the plastic injection molding process to produce a large volume of a particular part, for several main reasons:

Use cases for injection molding vary widely; it can be used to manufacture molds and parts from tiny components to large automotive parts.

Our team is sure to review parts and tolerances on a case-by-case basis for all plastic injection molding quotes to ensure that we can deliver on all objections and achieve optimal part quality.

Injection molding is a perfect solution for scaling large volume or mass production due to the simplicity and consistency of the process. Standardized injection molds allow manufacturers to dial in the specific requirements of their product and reproduce them quickly and accurately.

The high injection pressure means that the molten material fills all of the mold’s cavities and forms a solid part. Through the cooling process, it hardens to the shape of the cavity, creating the desired product.

Depending on your application, certain materials may be more suitable than others. For example, if you need a high-strength but flexible material to fill your mold tool, thermoplastic materials like ABS might be best. High-density polyethylene, on the other hand, features a high chemical resistance, making it suitable for products or components that will be exposed to moisture or chemicals.

As veterans in high-performance polymers and engineered resins, you can rely on us to provide expert guidance on materials. All of our tooling is built to Class 103, 102, and 101 industry standards.

It also helps to keep assembly simple – the more parts required in the setup, the higher the cost, so it’s often beneficial to keep injection molded parts as self-contained as possible.

If a part is to be produced by injection molding, this must be considered in its design — this includes simplifying its geometry and number of components as much as possible. The mold should be designed with a goal of minimizing the risk of defects during the production process.

Toggle clamping uses the injection unit to melt the material, then inject it into a mold. In a process called metering, a screw then rotates to gather melted material from the hopper, until enough is accumulated to begin the injection process. The injection molding machine controls the injection speed via the rotation of the screw.

For injection molding, it’s prudent to minimize cycle time as much as possible. The more time you can cut from the cycle, the more money you’ll save.

Use cases for injection molding vary widely; it can be used to manufacture molds and parts from tiny components to large automotive parts.

Our mantra — “Driven by Dependability” — is founded on our adherence to our quality system, and remains the leading reason our customers keep coming back.