The expensive tooling required for automotive injection molding is a major drawback. Each injection molded part needs a unique tool, which increases the cost of the initial setup. Compared to huge, sophisticated molds made for full-scale manufacturing, tooling for simple designs and small production runs may cost between $2,000 and $5,000. To minimize these costs, working in partnership with an injection molding manufacturing partner can assist in optimizing the budget and improving mold designs.

Polycarbonate, a group of polymers with carbonate structures, stands out in automotive injection molding. Its unique structure enables transparency, transmitting light akin to glass. Automotive applications often leverage polycarbonate, crafting components like tail light housings, in which its optical properties and durability shine.

Aluminum mold inserts & flexible master mold concepts save time and provide the necessary tooling for your prototyping needs.

Elements like: instrument panels, air vents, and glove-box doors are efficiently manufactured through injection molding. Door handles, armrests, and panel trim are often produced using this process, ensuring precision and durability. Seat-belt parts, clips, and various interior trim pieces are injection-molded for seamless integration into the vehicle's interior.

A vertical injection moulding machine is able to produce high quality plastic parts at high speed and to overmould metal parts, for example. It has a direct vertical clamping system that eliminates the need for a separate clamping unit. In addition, the vertical orientation enables greater precision in the moulding of complex components compared to conventional injection moulding machines.

Injection molding excels in achieving precision for automotive part manufacturing. The process allows for intricate and accurate designs, ensuring that components meet exacting specifications, resulting in high-quality and consistent products.

We opted for a vertical sliding table ALLROUNDER 375 V 500 – 170 injection moulding machine from ARBURG. This high-performance machine has a clamping force of 500 kN and can produce parts with a shot weight of up to 80 grams. It is suitable for use in a wide range of industries and applications, including the automotive, electronics, medical and consumer goods industries.

Many under-the-hood parts, including: intake manifolds, covers, and fluid reservoirs, are injection-molded for their heat resistance and durability. Injection molding is used for battery housing, ensuring secure placement and protection within the engine compartment. Components like air filter housings are often crafted using this process to optimize airflow and performance.

Prototype only. This mold will be constructed in the least expensive manner possible to produce a very limited quantity of prototype parts. Also known as a Class V tool.

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Due to its distinct material properties, ABS (Acrylonitrile Butadiene Styrene) is a popular option in automotive injection molding. It combines acrylonitrile's chemical and thermal stability, butadiene's toughness and strength, and styrene's glossy sheen. Because ABS has a low melting point and is simple to shape, it is appropriate for many automotive applications, including coverings and dashboards that must be resilient and aesthetically pleasing.

The speed of automotive injection molding machinery, coupled with the efficient thermoplastic molding process, enables rapid production of automotive components. This swift manufacturing process makes it possible to mass-produce parts quickly, meeting the industry's demands for timely supply.

We have a reputation for taking on difficult projects and providing services like: thorough design for manufacturing (DFM) reviews, production part approval process (PPAP) submissions, a variety of material choices, and adaptable tooling solutions. We have received certification that our quality management systems meet the exacting requirements of IATF 16949 and the VDA. The talented experts at Xometry will expertly lead you through the injection molding procedure to provide premium car components.

Materials are used that exhibit chemical-physical adhesion to each other during injection molding. This is achieved either by using related materials (e.g. PP with TPE-S) or by modifying one of the two materials with a suitable adhesion promoter.

The vertical injection moulding machine can produce a wide range of plastic-metal composite parts (hybrid components) with high accuracy and precision.(…)

Rapid tooling is primarily about producing a functional prototype as quickly and cost-effectively as possible using injection molding.(…)

We are ISO 9001:2015 certified and AS9100D compliant. Only the top machine shops that apply to become suppliers make it through our qualification process.

protosys® Rapid Tooling is a component of our comprehensive range of engineering services. This ranges from the initial product idea, through material selection, design suitable for plastics, FEA structural analyses, injection molding simulations, laboratory tests and CT scans, to series production. The combination of development services with the material expertise of a compounder is unique. At BARLOG Plastics, you get the complete know-how from material formulation, compounding and product development to the finished plastic part from a single source.

The use of the Rapid Tooling process enables us to provide you with prototypes of optimum quality in the shortest possible time. By using aluminum mold inserts and flexible master mold concepts, we can extremely reduce machining times and tooling costs compared to steel molds.

Nylon, a versatile synthetic polymer family, is favored in automotive injection molding. Comprising polyamides with amide links, it's a thermoplastic with a silky texture, ideal for crafting fibers, films, and various shapes. Automotive applications frequently involve using nylon to create components such as bushes and bearings, making it an essential material for durability and performance.

If your component geometry can be manufactured by injection molding, then we can also represent it in the rapid tooling process. We will be happy to advise you on design suitable for production and plastics and verify manufacturability using injection molding simulations in our CAE department.

Send us your request via our offer form. There you can also transfer your 3D data securely and encrypted and we guarantee the confidentiality of your data and your request. Our experts will check your request immediately and usually provide you with your personal, free and non-binding offer within one working day after receiving complete request data.

Automotive injection molding offers remarkable design flexibility for automotive part design. With a wide range of molds available, it becomes easier to create plastic components with intricate or unique shapes, without sacrificing production efficiency. This adaptability enables the development of innovative and distinctive automotive components.

Rapid tooling is primarily about producing a functional prototype as quickly and cost-effectively as possible using injection molding.(…)

In order to be able to offer our customers these advantages, we do not build complete molds in the rapid tooling process but mold inserts for our master molds. These consist of two molding halves, with or without slides, and the ejector. Our master mold, together with the mold insert produced for you, then forms a functional injection mold.

Low production mold. Use only for limited production preferably with non-abrasive materials. Low to moderate price range. Also known as a Class IV tool.

Plastics are very versatile materials and offer product developers a wide range of material properties to produce high-quality components at low cost.

Rapid tooling is primarily about producing a functional prototype as quickly and cost-effectively as possible using injection molding.

Medium production mold. This is a very popular mold for low to medium production needs. Most common price range. Also known as a Class III tool.

Stamping is a common method for shaping metal components in the automotive industry. It involves compressing a metal sheet between dies. Stamping is advantageous for its high-speed production, making it cost-effective for large quantities of components like body panels and structural parts. However, it may not be as versatile as injection molding for complex part geometries. Automobile manufacturers find value in employing metal stamping for components such as fenders due to the reusability of dies, ensuring the consistent production of parts.

In order to nevertheless keep the number of necessary components as low as possible and save assembly processes, multi-component injection molding is a manufacturing process in which a component is made from several materials in a single production step.

Injection molding is a highly automated process, which reduces labor costs significantly. This automation contributes to cost efficiency, especially for large-scale production.

Automotive injection molding stands out for its exceptional material efficiency. The process minimizes waste generation, as it precisely shapes components with minimal excess material. This efficiency not only translates into cost savings but also promotes environmental sustainability by reducing material waste and the associated environmental impact, aligning with modern eco-conscious manufacturing practices.

Choose from millions of possible combinations of materials, finishes, injection molding tolerances, markings, and certifications, including ISO 13485, for your order.

The process of automotive injection molding comes with certain limitations, particularly when molding complex automotive parts. Designers must consider factors such as wall thickness uniformity and the filling performance of injection molding, which can influence the manufacturability and quality of the components.

We process all thermoplastics. Starting with standard plastics (e.g. PE), through technical thermoplastics (e.g. PBT / PA) to high-performance plastics (e.g. PEEK) and even LSR – liquid silicone. The material application possibilities are manifold.

Polypropylene, a key player in automotive injection molding, is a synthetic resin renowned for its polymerization of propylene. As part of the polyolefin resin family, it excels in creating plastic products that demand lightweight properties, toughness, and flexibility. Automotive applications benefit from its usage in crafting external components like bumpers, as well as for cable insulation, highlighting its versatile role in the industry.

Alternative manufacturing methods for automotive components offer distinct advantages and disadvantages compared to injection molding. Here are some notable alternatives:

Here you benefit from the interaction of BARLOG Plastics, because we offer an extensive range of adhesion-modified plastics and has many years of experience in the modification of materials for 2C injection molding, so that we can provide you with competent advice on the production of prototypes and small series from the idea to the series from a single source.

We are happy to offer laser marking, ultrasonic welding and component assembly for further processing of your components.

Medium to high production, good for abrasive materials and/or parts requiring close tolerance. This is a high quality, fairly high priced mold. Also known as a Class II tool.

Range of finishes from Grade 3 diamond / high polish to 320 stone low polish. Finishes include: SPI A-1 SPI A-2 SPI A-3 SPI B-1 SPI B-2 SPI B-3 SPI C-1 SPI C-2 SPI C-3 SPI D-1

The sandwich injection molding process also makes it possible to combine several properties in one injection molded part and achieve functional integration. The special feature of this process is the possibility of achieving a layer structure with a closed outer skin, e.g. in order to use a decorative material on the outside and a functional material on the inside, largely invisibly. Examples of applications for sandwich injection molding include chrome-plated door actuation levers in automotive interiors or our Carabiner 2.0. The inner layer of this consists of a carbon fiber reinforced POM (KEBAFORM C904 CF black) to achieve the required strength and rigidity. In order to simultaneously achieve the flexibility and spring action for the hinge function of the snapper without having to mount additional components, the outer skin is made of unreinforced POM (KEBAFORM C90.0 red).

Multiple-cavity steel tooling with full automation and overnight production workcenters for dedicated part manufacturing.

The particular challenge in the 2C process is that the cavity of the second component must be adapted to the injection molded part of the first component so that overmolding is avoided.

Plastics are very versatile materials and offer product developers a wide range of material properties to produce high-quality components at low cost.

Built for extremely high production. This is the highest-priced mold and is made with only the highest quality materials. Also known as a Class I tool.

Whether standard injection molding, multi-component injection molding, sandwich injection molding, foaming, silicone injection molding, in-mold labeling, gas injection technology or the overmolding of metal inserts – our process is tailored to your requirements.

Automotive injection molding stands out as a cost-efficient solution for component production. Many metal parts are costlier to manufacture than their plastic counterparts. Scarce resources often drive up the price of metals used in automotive components like wheel rims and chassis, making plastics a more economical choice.

For your free quote and design-for-manufacturability feedback, please upload your CAD file, or download our Injection Molding Design Guide. We want to earn your business. If you get a lower injection molding quote, send it to us and we will try to beat it.

Our extensive machinery is at your disposal for the production of your components. In addition to our standard injection molding machines (clamping force between 6 to – 450 to) and our 2K machine (clamping force 50 to), we even offer you a vertical injection molding machine (clamping force 50 to) for the production of plastic-metal composite parts.

Quality standards that also inspire our customers. Our high-quality and near-series prototypes are produced quickly and cost-effectively.

The vertical injection moulding machine can produce a wide range of plastic-metal composite parts (hybrid components) with high accuracy and precision.(…)

Liquid silicone rubber processing requires sophisticated process engineering, which BARLOG Plastics has optimized for the LSR prototype sector. Due to the low viscosity of LSR, BARLOG Plastics can process the components directly by injection molding using a mixing and metering system. Special units are used on the injection molding machine for this so-called liquid injection molding.

Based on your 3D component design, we manufacture aluminum mold inserts on our HSC milling machines and fit them into our flexible master mold system. In the rapid tooling process, we mostly produce injection-molded prototypes. However, it is just as suitable for the production of pilot series, as bridge tooling and for the production of small series.

Injection molding yields lightweight and impact-resistant bumpers, safeguarding both aesthetics and safety. Vehicle grilles are often molded, combining design intricacies with functionality. Exterior mirror housings are frequently produced using this method for their durability and design flexibility.

Xometry's injection molding service has decades of experience making plastic parts used in automotive applications. Our strength is in saying "yes" - we help our customers make parts that others can't make. Automotive companies large and small have found value in our highly customized services including:

Plastics are very versatile materials and offer product developers a wide range of material properties for producing high-quality components at low cost. In particular, the possibilities for saving components through function integration offer considerable potential. Frequently, however, the various functions that a product is supposed to have are so different that one material alone cannot fulfill them.

Undercuts or openings are made in the geometry of the first component (usually the hard component in hard/soft composites), which are then filled with the second (soft) component. This creates a mechanical interlock and thus also allows chemically incompatible materials to be combined.

In addition to standard injection molding on machines from 60 to 4500 kN clamping force, we also offer injection molding prototypes and small series in special processes, such as multi-component injection molding, sandwich injection molding, foaming, silicone injection molding or gas injection technology. Overmolding of metal inserts or inmold labeling are also common injection molding processes. In addition, we also offer further processing of your components, for example by laser marking, ultrasonic welding and component assembly.

With the vertical injection moulding machine, a wide range of plastic-metal composite parts (hybrid components) can be produced with high accuracy and precision. Last but not least, the use of the sliding table enables more repeatable and also faster cycle times in the semi-automatic process, for example with metal inserts. In summary, this type of production offers a more cost-effective, faster and more precise alternative, especially in the medium to high volume range.

Range of finishes including matte, swirls, lines, and patterns. Finishes include: MoldTech - MT11010 MoldTech - MT11020 MoldTech - MT11030 MoldTech - MT112XX MoldTech - MT114XX MoldTech - MT116XX

When manufacturing parts in bulk, automotive injection molding's cost-effectiveness clearly shows. The method is a favorite for high-production runs in the automobile sector due to its effectiveness and low cost per unit. High tooling costs are a considerable disadvantage for lesser volumes, though, leading to the consideration of alternative manufacturing processes that are more cost-effective for smaller-scale production.

The injection molding industry often defines molds by their class. This goes from Class 105, a prototype mold (e.g., a 100 piece one-and-done market test), to Class 101, which is built for extremely high production (e.g., making tens-of-millions contact lens cases). Xometry typically produces Class 104, 103, and 102 tools.

It might be difficult to choose the right materials for injection-molded automotive parts. Heat resistance, chemical compatibility, and structural specifications may all have an impact on the variety of materials that are available for a certain application.

Our vertical injection molding machine is capable of producing high quality plastic parts at high speed and overmolding metal parts, for example. Due to the direct vertical clamping system, no separate clamping unit is required. With a clamping force of 50 tons, it can produce parts with a shot weight of up to 80 grams. Our vertical molding machine is suitable for use in a wide range of industries and applications, including automotive, electronics, medical and consumer goods.

You have full material freedom and can provide us with any plastic for your project. We will also be happy to procure your desired material through our network. But the quickest way is to select one of the more than 200 materials we have in stock at all times. And if you have very special requirements, we will even develop your personal plastic with customized properties.

Applications of automotive injection molding encompass a wide array of components, enhancing the functionality and aesthetics of vehicles. Some of these applications are listed below:

Complicated details, such as plastic-metal composite parts, which were only possible to a limited extent with previous injection moulding machines, can thus be produced without any problems.

With non-reinforced standard plastics, we can easily offer small series of up to 50,000 units per year over several years. In the case of reinforced plastics, special coatings are used for the mold inserts in order to optimize the service life of the mold inserts and minimize maintenance requirements. In individual cases, however, we also use mold inserts made of steel from the outset in order to be able to guarantee your desired quantities.

The question cannot be answered in such a general way, but as soon as you need near-series components made of original material for real tests, the rapid tooling process is the clear favorite. The advantages: Free material selection, high surface quality (with or without structure) and no compromises in the quality and properties of the material. And already from 10 pieces, rapid tooling can have commercial advantages over 3D printing.

The protosys® services from BARLOG Plastics can now be used in the development phase with fully functional components made of LSR series material.(…)

Such components are of course not realized fully automatically in our rapid tooling process, as in large-scale production, but semi-automatically. The hard component is injected in a cavity and this is then manually inserted into the cavity of the soft component and overmolded.

Die casting is another alternative method used in the automotive industry, primarily for manufacturing parts from metals like aluminum and zinc. It is favored for its ability to create highly detailed and complex parts with tight tolerances. Metal injection molding is ideal for intricate small parts and large-scale production but involves many steps. Conversely, die casting, with fewer steps, is cost-effective for both small and large runs. Die casting is integral to the automotive sector, serving various roles like crafting engine components and producing brackets for stepper and electric motors.

Reliability is a top priority for us. We always meet promised deadlines and thus offer you the highest degree of planning security.

If a plastic can be thermoplastically processed by injection molding, we can also use it for the production of prototypes and small series in the rapid tooling process. Regardless of whether standard plastics such as PE, PP or PS, technical thermoplastics such as PA, PBT or ABS or high-performance plastics such as PPA, PPS or PEEK. The possibilities for material selection are unlimited and even highly filled, fiber-reinforced or slip-optimized plastics are no problem – the full freedom of the injection molding process.

The mold inserts are usually made of aluminum. This material combines good machinability with an excellent service life for prototypes and small series. Depending on the plastic processed, quantities of up to 30,000 units per cavity can be produced with the aid of a special anti-wear coating.

CNC automotive machining refers to a broad range of operations that can be successfully used on a variety of materials, including: metals, polymers, and composites. These operations include: CNC turning, milling, and drilling. It is particularly well suited for the production of complex automotive components, including: lighting systems, engines, and gearboxes because of its adaptability and versatility. Contrasting with injection molding's strength in mass manufacture of plastic parts, CNC machining is often chosen for custom or low-volume production as well as the creation of prototypes, in which precision and customization are important.

For example, high-strength housings with integrated, flexible seals or tool handles with soft haptic components can be produced. An example of multicomponent injection molding that everyone is familiar with from everyday use is toothbrushes – here, 5 or more different materials are often combined in a single production step to create a final product.

The automotive injection molding services provided by Xometry are evidence of our dedication to accuracy and quality in the manufacture of plastic parts for the automobile sector. We excel at mold design and have vast experience in precision custom molding for automobile parts. Our use of automotive-grade materials demonstrates our commitment to excellence and ensures that our products are durable and reliable.Â

For automobile injection molding, Xometry only uses sophisticated thermoplastic materials and plastics of the highest quality. The selection of these materials ensures that the produced components fit the stringent requirements of the automobile sector thanks to their remarkable durability, chemical resistance, and lightweight qualities. We use the following materials for injection molding:

Thanks to our certified quality management system according to ISO 9001:2015, change management is ensured during the ongoing project. The rapid tooling concept with mold inserts in master molds enables virtually unlimited change grinding of your component geometry, which we realize for you quickly, easily and cost-effectively.

The protosys® services of BARLOG Plastics can now be worked with fully functional components made of LSR series material already in the development phase. For this purpose, BARLOG Plastics produces an liquid silicone rubber prototype using injection molding from the customer’s virtual 3D CAD component via mold design, including rapid tooling. You benefit directly from near-series experience and results, and do so particularly quickly, cost-effectively and efficiently.

Moldmaker's choice of finish. Typically SPI B-3 to D-3 depending on geometry and drafts. Interior, non-cosmetic faces, are typically as-machined.

The protosys® services from BARLOG Plastics can now be used in the development phase with fully functional components made of LSR series material.(…)

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Designing automotive parts for injection molding can be complex. Achieving the desired geometry, tolerances, and surface finishes while adhering to manufacturing limitations can be challenging. Designers must carefully navigate these complexities to ensure that the final components meet both functional and aesthetic requirements.

The sandwich process was originally developed to make low-cost recycled material disappear inconspicuously inside a plastic part. As is so often the case, the inventors did not realize the true potential of their invention until later.

Since the production of multi-component injection molded parts is usually associated with high tooling costs, this technology has so far mainly been used for large quantities. Our protosys business unit has many years of experience in multi-component injection molding and also offers the possibilities of this technology in the rapid tooling process for the production of injection-molded prototypes or even for the realization of your small series production.

The Automotive Injection Molding Process at Xometry is a meticulously structured journey from tooling design to production. Our knowledgeable team carefully coordinates the design of the tooling and controls the mold-making process. The efficiency of molding cycles is improved without sacrificing quality. To ensure that automobile components meet the highest requirements and create products that excel in durability and precision, strict quality control methods are used throughout the process.

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In the sandwich injection molding process, the mold is partially pre-filled with the material that will later be on the outside. The second component is then injected through the same gating point, displacing the still plastic first material and thus forming an inner layer with different properties. In this way, components are obtained which also fulfill supposedly contradictory requirements, such as strength and flexibility or function and decoration in equal measure.

Our protosys® business unit specializes in the production of high-quality prototypes made of plastic. We process all thermoplastics from PE to PEEK, thermoplastic elastomers and liquid silicone (LSR).