Although it is very popular among industrialists, no one can deny that some misconceptions and facts exist about the cost of injection molding. This technology may prove expensive if you do not know how to optimize various interlinked elements and factors.

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Material cost=[(1 Material loss) * Product weight * Batch adjustment loss Material weight Normal scrap rate * Product weight * Batch] * Material unit price/Batch

Sulapac’s patent pending innovation is a perfect fit for cosmetic brands seeking for a sustainable packaging for water-based formulas. Used as the inner layer of a jar, it provides an excellent barrier against water evaporation and enables you to pack your emulsions in beautiful, bio-based and biodegradable Sulapac packaging. The weight loss of Sulapac Barrier in one year (demonstrated shelf life) is well below 3%1, which is the typically accepted maximum weight loss for cosmetic packaging.

Sulapac Universal Heat 30 is a sustainable, beautiful, and functional material for injection molding containing 70% USDA certified biobased content. The material is optimized for high heat resistance without additional or post-treatment, with ideal flexural strain and impact strength, making it a great option for single-use and reusable cutlery1 with outstanding usability.

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Sulapac Universal Flex 35 is safe for both people and the planet: the material is certified as industrially compostable by BPI1 and leaves no persistent microplastics2 or toxic load behind. Universal Flex 35 meets the EU and US FDA requirements for food contact materials for dry food3 .

The material contains 100% USDA certified biobased content. Sulapac Solid has low carbon footprint2, and it is certified as industrially compostable by BPI3. It doesn’t leave persistent microplastics or toxic load behind4. Furthermore, the material is certified chemically recyclable by LOOPLA technology.

20,57 kg CO2 eq/kg based on cradle-to-gate LCA performed by an independent third-party consultancy (biogenic carbon included).

2 Ecotoxicity and threshold values for heavy metals tested according to EN 13432. The material complies with the EU and US FDA food contact requirements (restrictions and specifications of use apply, further information in Declaration of Compliance).

The material loss is generally 3% -5%; The weight of materials lost during machine adjustment and the weight of normal scrapped products are generally 5000g –15000g

Whether you start your injection molding for a low, medium, or high production volume, each one has its own pricing factors.

Please note that if the end product needs to be resistant to high temperatures (HDT-B 130 °C)6, the minimum mold temperature is 100°C7.

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Injection molding costs would be expensive or affordable; it is your choice and your tendency toward research and calculation. If you try to do your research and optimize these crucial factors in accordance with your requirements, you could minimize confusion.

1 Sulapac materials within the same family of recipes show biodegradation of 26-60% at 140 days in the marine environment (30ºC / 86ºF) (ASTM D6691).

3D printing is the best choice for complex geometries at affordable pricing, whereas CNC machining is great for very hard complex geometries, although it would be costly. EDM machining is relevant for creating a mold from hard and conductive materials.

1Material is suitable for repeated use as per European Commission regulation (EU) No 10/2011. Dishwashability tested according to EN 12875 standard with 125 washing cycles.

Mostly steel and aluminum are preferred by manufacturers. Aluminum molds are lightweight, rust- and heat-resistant, and highly formable. Steel molds are good for high production and where high durability is in demand, although they are expensive.

Sulapac Universal Flex 35 is a sustainable, beautiful, and functional injection molding material which contains 87% USDA certified bio-based content. The material is designed for thin-walled structures with good impact strength and is easy to process with minimal, if any adjustments needed for the existing machinery.

1 Suitable for reusable applications as per European Commission regulation (EU) No 10/2011. Dishwashability tested according to EN 12875 standard with 20 washing cycles.

To maximise the functionality of your end product, there’s a range of material grades you can choose from with different flexural and tensile properties, heat resistance and density. In terms of look & feel, you can opt for a natural appearance with large wood chips or a smooth polished surface, or something in between!

If your demand is for low-volume manufacturing, go for 3D printing technology and aluminum material in order to get low costs for injection molding.

The incurring of tooling costs plays a crucial role in the determination of the injection molding cost. Here are the parameters on which a whole stake in tooling costs relies.

Sulapac Universal Heat 30 is safe for people and the planet: It is made of industrially compostable raw-materials and leaves no permanent microplastic2 or toxic load behind.

4Relative biodegradation of 77,3% in 420 days in simulated marine environment test (ASTM D6691 86 °F/30 °C) using natural sea water. Not considered biodegradable in California

The higher the mold cavity, the more pressurizing power and time a tool requires. As a result, the reduction in production speed increases the injection molding cost.

Sulapac® materials are the sustainable, beautiful, and functional alternative to conventional plastic. Start using Sulapac with your existing injection molding equipment and gain competitive advantage through sustainability and innovation.

If you attempt to incorporate the injection molding technique for a huge production, there is no doubt that it will bring many benefits, including cost-effectiveness as one of them.

1The compostability has been tested up to the thickness of 1,48 mm. As the compostability of an end product is also dependent on the geometry of product, it is the responsibility of the manufacturer of the end product to ensure compliance with the regulations.

Sulapac® materials are the sustainable, beautiful, and functional alternative to conventional plastic. Start using Sulapac with your existing injection molding equipment and gain competitive advantage through sustainability and innovation.

Injection molding is a favorite technique for plastic manufacturers in the mass production of many plastic parts or components. The rise in demand for this manufacturing technology makes it a crucial factor in running the plastic industry.

3  Raw materials fulfil the requirements for heavy metal tresholds and ecotoxicity according to EN13432 and ASTM D6400.The material complies with the EU and US FDA food contact requirements (restrictions and specifications of use apply, further information in Declaration of Compliance).

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3Restrictions and specifications of use apply, please refer to relevant Declaration of Compliance for further information.

Processing cost=(machine adjustment time/batch forming time/number of mold holes) * Injection molding machine worker salary

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Sulapac® materials can be used with existing injection molding machinery, enabling a resource efficient transition towards a cleaner future.

6Sulapac Solid has been tested for per-and polyfluoroalkyl substances (PFAS) by an independent laboratory (ISO/IEC 17025 certified) based on CEN/TS 15968 test method; No PFAS compounds were detected.

Sulapac Premium is made of wood chips from industrial side streams combined with biodegradable biopolymers. This 100% bio-based material biodegrades without leaving persistent microplastics behind1.

5 As the compostability of an end product is also dependent on the geometry of product, it is the responsibility of the manufacturer of the end product to ensure compliance with the regulations.

The Sulapac Premium material makes your products look and feel luxurious. This grade of Premium is more flexible and has a better impact strength. The visible wood chips and haptic touch make it stand out. It is ideal for brands that value sustainability while aiming for that exclusive feel.

Our experts are happy to support you in choosing the right material. Contact our sales to discuss more or ask for a quote.

2Biodegradation of 79% in 308 days in the marine environment (30 °C / 86 °F) (ASTM D6691). Tested according to ASTM 5511 (accelerated biodegradation in the landfill 37°C / 99 °F): 52% relative biodegradation in 210 d. Not considered biodegradable in California.

The material is processable with existing injection molding machinery. Our experts assist with the tests and production settings from mold selection to nozzle size.

Sulapac Luxe Flex is a sustainable material for injection molding ideal for replacing hard plastics like ABS. Luxe Flex can be used to manufacture fragrance caps, cosmetic jars, lids, compact powder boxes, and pencils, for example. The material is resistant to temperature fluctuations, has a high density and a premium look and feel, even sound. With Sulapac Luxe both shiny and matt surface can be achieved depending on your mold selection. The material has excellent processability and it is easy to color with Sulapac masterbatches. Luxe Flex is now also available as black granules!

4  Can be recycled through hydrolysis back to monomers, suitable as feedstock for recycled biopolymers. Mechanical and chemical recyclability tested and proven technically feasible by third parties. Field tests have also verified that Sulapac materials can be collected and sorted out of a mixed waste stream. When collected together, Sulapac materials do not interfere with the current mechanical recycling of conventional fossil- based or bio-based non-biodegradable plastics. The technology for chemical recycling of bio-based and biodegradable materials exists, but the infrastructure is still under development.

Steel materials and CNC machining are good for medium- and high-volume production. But manufacturing in high volume reduces the cost per part manufactured compared to medium-volume production.

Mold design for complex components demands high costs and skilled expertise. It is the outcomes that you pay for in an injection molding project.

4 Can be recycled through hydrolysis back to monomers, suitable as feedstock for recycled biopolymers. Mechanical and chemical recyclability tested and proven technically feasible by third parties. Field tests have also verified that Sulapac materials can be collected and sorted out of a mixed waste stream. When collected together, Sulapac materials do not interfere with the current mechanical recycling of conventional fossil-based or bio-based non-biodegradable plastics. The technology for chemical recycling of bio-based and biodegradable materials exists, but the infrastructure is still under development.

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In this way, it is very essential for you to determine the injection molding cost before the inception of your assembly line to produce products.

1 Material version with USDA Certified Biobased Product label (certification mark of the U.S. Department of Agriculture) available.

Mold Trail Cost: Large and medium-sized molds can be controlled within 3%, and small precision molds can be controlled within 5%;

The Universal Flex 30 is ideal for single-use and reusable cutlery that ensures easy mass-manufacturing and outstanding usability. Beautiful and sustainable option for injection molding. Ideal flexural strain and impact strength for complicated designs like knives and forks. Suitable for food contact according to EU and FDA.1

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2  Relative biodegradation of 49,7 % in 308 days in simulated marine environment test (ASTM D6691 86 °F / 30 °C) using natural sea water. Not considered biodegradable in California.

The Sulapac Premium material makes your products look and feel luxurious. The ceramic sound and visible wood chips’ haptic touch make it stand out. It is ideal for sustainable products that aim for an exclusive feel.

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3 Fully biodegradable in simulated marine environment tests according to ISO 22403 and ASTM D6691. Relative biodegradation of 100% (ISO 22403, 27°C / 80°F) and 92% (ASTM D6691, 30°C / 86°F) in 56 days using natural sea water. Not considered biodegradable in California.

Sulapac materials for injection molding are sustainable alternatives for PS, ABS, PC and PP. They can be used for various applications including cosmetic packaging, kitchenware, and cutlery.

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Sulapac Luxe Flex contains 73-86 % USDA certified biobased content1, sustainably sourced biodegradable biopolymers being the main raw material. Sulapac Luxe Flex is safe for people and planet2. It has been certified industrially compostable by TÜV Austria.3 The material is recyclable by design and can also be made with recycled content.4 Available as non-GMO; ask more from your account executive!

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Sulapac Luxe is the ultimate answer for brands looking for a sustainable yet luxurious replacement for hard plastics like ABS. Sulapac Luxe is ideal for fragrance bottle caps, jars, and lids.

2 Biodegradation of 56,7% in 280 days in the marine environment ASTM D6691(86°F / 30°C). Not considered biodegradable in California.

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The material is processable with existing injection molding machinery. Our experts assist with the tests and production settings from mold selection to nozzle size.

This bio-based (87%) material is safe for people and the planet: it is industrially compostable and biodegrades without leaving persistent microplastics behind1.

Sulapac Solid is a sustainable injection molding material ideal for kitchenware used on a daily basis, such as plates, mugs, bowls and containers. It has high impact strength and it is dishwasher1 and microwave safe. The material is available in natural, white and black color.

Universal material is made of wood from side streams and biodegradable biopolymers. This 100% bio-based material biodegrades without leaving persistent microplastics behind1.

Relative biodegradation of 70% in 58 days when tested in simulated solid-state anaerobic condition (ASTM D5511, 37°C / 99 ºF) representing an accelerated biodegradation in a landfill.

3The compostability has been tested up to the thickness of 150μm according to BPI (ASTM D6400). As the compostability of an end product is also dependent on the geometry of product, it is the responsibility of the manufacturer of the end product to ensure compliance with the regulations.

5Restrictions and specifications of use apply, please refer to the relevant Declaration of Compliance for further information.

Replace your traditional plastic material and start mass-producing truly sustainable products with minimal investment. Universal material is designed to fit to existing production lines and molds. It is suitable for rigid products such as jars and hangers. Technical specification and easy processing instructions are available in the technical datasheet.

Part DFM analysis is very beneficial in terms of reducing errors and part costs and boosting productivity and efficiency. It is because it ensures that CAD design is optimized for assembly and manufacturing.

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The material has high density, good resistance to temperature fluctuations and a unique, ceramic look and feel, even sound. With Luxe both shiny or a matt surface can be achieved depending on your mold selection.

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1 Sulapac Universal Flex 30 meets the EU and US FDA requirements for food contact materials. Restrictions and specifications of use apply, please ask for Declaration of Compliance for further information.

4 Restrictions and specifications of use apply, please refer to the relevant Declaration of Compliance for further information.

1Biodegradation of 48%–59% in 280 days in the marine environment (30ºC/86ºF) (ASTM D6691). Tested also according to ASTM 5511 (accelerated biodegradation in the landfill, 37ºC/99ºF): 68% relative biodegradation in 160 days. Not considered degradable in California.

The unique combination of raw materials: responsibly sourced biodegradable biopolymers and naturally occurring clay minerals, gives Sulapac Solid its beautiful ceramic look and feel, even sound, that makes it stand out. Sulapac Solid meets the EU and FDA requirements for food contact materials5 and it contains zero PFAS6.

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Replace conventional plastic with the beautiful, functional and sustainable Sulapac material. We will help you to make the switch smoothly.

7 The heat resistance of the end product is dependent on the geometry and the manufacturing process of the product. It is the responsibility of the manufacturer of the end product to test and validate the maximum usage temperature and optimize the manufacturing process.

It is right to say that it would prove costly if you harnessed it for a small quantity of production instead of mass production.

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3 Restrictions and specifications of use apply, please refer to relevant Declaration of Compliance for further information.

The larger the part size, the bigger the injection molding machine, and the more sophisticated the mold manufacturing procedure. As a result, the higher the injection molding cost.

The material mentioned here refers to the material of the mold and the material of the product. Most designers are well versed in the materials of their products. Injection molding harnesses mostly thermoplastics (PEEK), and it is very affordable. For example, it can cost between $1 and $5 per kilogram. How to select the right material for injection molds is also very important.

Wish for extreme part complexity to improve aesthetics? CNC machining can do this but bill your budget due to longer production times, longer cycle times, and the consumption of more material, ultimately resulting in higher costs.

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Sulapac Barrier contains 98% USDA certified biobased content2 and biodegrades without leaving persistent microplastics3 or toxic load behind. The material is food contact compliant4 and certified industrially compostable by BPI5.

2 Sulapac materials within the same family of recipes show biodegradation of 57,6% at 462 days in the marine environment (30ºC / 86ºF) (ASTM D6691), 28% at 153 days when tested according to ASTM 5511 (99 ºF) accelerated biodegradation in the landfill.

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As you have heard a lot about many misconceptions, like injection molding would be very expensive, they are not true in the fullest sense.

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This article unveils everything related to the calculation of the injection molding cost in order to make you knowledgeable and informed. Ready to get aware of how much injection molding costs? Be calm and stay with us.

Sulapac Luxe contains 73-87% USDA certified biobased content1, sustainably sourced biodegradable biopolymers and non-visible wood flour from industrial side streams being the main components. The material is safe for people and the planet: it leaves no persistent microplastic2 or toxic load3 behind. Sulapac Luxe is recyclable by design4 and can also be made with recycled content.