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RSP is a manufacturer with expertise to bring a product from concept to realization through custom silicone molds, plastic molding and more. RSP focuses on complete solutions including assembly and packaging.

RSP is using eco-friendlier plastics to reduce environmental impact in the molding industry. RSP biocomposite plastics include hemp, rice, flax or cotton fibers added to petroleum-based plastic. This reduces the amount of plastic that is used, which in turn reduces pollution.

Multi-shot injection molding, also known as multi-color injection molding, refers to the process where two or more colors or different materials are molded using a mold with one or more channels. Historically, dual-color injection molding was the pioneer in this field. A common example many of us interact with daily is the toothbrush. The handle of most toothbrushes is produced using dual-color injection molding, typically combining PP (hard plastic) with TPE (soft plastic). TPE is chosen because of its excellent compatibility with PP, and the soft plastic overlay enhances the grip.

In the design of multi-color/multi-material injection molded products, two primary methods are used to join adjacent components:

7. The product from the first injection can be slightly oversized. This ensures a tighter fit during the second molding, achieving a better sealing effect.

Products made using multi-color injection molding have a significantly different structure compared to regular plastic products. When designing the structure and shape of these products, it’s essential to consider their intended use and purpose. It’s crucial to delve deep into the structural design of the injection-molded product, taking into account the compatibility features of the various materials used. Typically, the design aims to increase the contact area of the raw materials to enhance solidity. This can be achieved by incorporating numerous small recesses and protrusions within the product, which serve to increase the material’s contact area, thereby improving the product’s strength, lifespan, and practicality.

11. To achieve tighter bonding between materials, consider the “stickiness” between materials and the roughness of the mold surface.

3. Before designing the mold, it’s crucial to understand the parameters of the multi-color injection molding machine intended for mass production. This includes data like maximum/minimum mold capacity, mold thickness, and the distance between ejector pins.

RSP applies the same high standards and quality to every plastic injection molding project we undertake. It starts with our senior engineering team that together have over 100 years of plastic molding experience. It continues with our investments in new facilities and equipment. Our team is dedicated to quality and has achieved ISO13485 certifications for medical-grade molding. We are also FDA registered for manufacturing medical devices. Even if your project is not medical in nature, you can rest assured the controls and processes are in place to ensure success and quality. Internally, we use GBT 14486-2008 molding tolerances and also work with clients on critical measurements.

Plastic injection molding services include plastic engineering, design review, mold flow analysis, tooling design and fabrication, and molding of parts. RSP offers clients the highest level of quality and professionalism regardless of quantity. Our team is available to answer questions and keep you informed during the process at every step. Once we move into the tooling phase, you will receive weekly updates with notes and images so you can see firsthand how your project is developing.

If you are like many of our customers, you think about your product 24/7. You dream of how it will change the market, or maybe you’re creating a brand-new market. But when it comes to executing the product, you’ve realized you need some help. That’s where we come in.

RSP is part of a growing group of manufacturers that have officially joined Oceanworks® and make products from ocean plastic. We supply and manufacture with ocean plastic for several companies that produce consumer products and reusable packaging solutions. These companies are proud to be part of the solution to create a more sustainable environment while meeting an ever-increasing demand for responsibly made products. Contact us today to see whether ocean plastic is a good fit for your next product.

Integrating more than 50 years of manufacturing knowledge with current best practices and technology, we offer a variety of injection molding services and value-added processes to meet all of your needs, from single components to full custom turnkey manufacturing.

Multi-shot injection molding requires a high level of process and plant resources. This plastic-making method has changed how we design and make products, making them look and work better. As industries continue to seek innovative solutions, Prototool emerges as a leader in the field, specializing in plastic products and parts manufacturing using the two-shot injection molding process and multi-shot techniques. With a commitment to precision, quality, and cutting-edge technology, Prototool is not just a manufacturer but a partner for businesses aiming for excellence. As we navigate the future of plastic manufacturing, aligning with pioneers like Prototool ensures a journey marked by innovation, efficiency, and unparalleled expertise.

Adding a textured finish to the surface of TPE products can give a leather-like feel, enhancing tactile sensation and masking surface imperfections. Some textures can also adjust the surface hardness of TPE products, making them softer or harder than when made with a smooth TPE surface. If designers polish the TPE surface to a mirror finish, it may exhibit many flow lines and color streaks, or it may turn white during use, degrading the surface quality.

2. It’s imperative to ensure that after the back mold rotates around its center, it aligns perfectly with the front mold. This aspect requires careful attention during design.

Interested in learning more about our plastic, ocean plastic and bioplastic injection molding process and what we can do to help manufacture your product? Start by filling out the information below so we can get a good understanding of what you may need from us. We will respond as quickly as possible to your request; however, please allow at least 24 business hours.

Taking TPE overmolding as an example, given the high cost of TPE material, designers must consider cost reduction during product design by using a thinner TPE wall. The tactile feel of TPE is directly related to its wall thickness and hardness. When the TPE thickness is less than 1.5mm, the softness or hardness is primarily influenced by the hardness of the underlying hard plastic. Reducing the thickness of TPE can severely affect its bonding strength with the hard plastic, mainly because an overly thin TPE cools too quickly in the mold, leading to reduced adhesion strength.

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8. It’s essential to consider whether the flow of plastic during the second injection might disturb the already molded product from the first injection, causing deformation. If this is a possibility, remedial measures should be taken.

6. When designing the cavity for the second injection, some voids can be incorporated to prevent the newly formed product from being scratched or scraped by the mold. However, it’s crucial to carefully assess the strength of each sealing position to ensure that no flash occurs due to high injection pressures.

The seal position refers to the junction or boundary between hard and soft plastics. A good design avoids a “feathered” appearance (i.e., the seal position shouldn’t gradually thin out), as overly thin edges can lead to poor adhesion and warping. Ideally, the design at the seal position should have a distinct step or recess to ensure consistent wall thickness. In some products, especially those with long flow paths or areas prone to wear, mechanical connections can be designed between the soft and hard plastics, ensuring a strong bond between the two materials.

5. Choosing the right material is vital. Consider factors like the material’s adhesiveness, potential deformation during injection, and risks associated with melting.

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Our cross-functional experience allows us to assist all customers in meeting their plastic manufacturing objectives. We have experience with the following industries:

4. The sprue of a three-plate mold should ideally be designed for automatic demolding. Special attention should be paid to ensure the reliable demolding action of the soft plastic sprue.

Here is a great chart to help you plan what to expect depending what type of injection molding project you are looking to complete.

Plastic injection services can vary in pricing depending on the complexity of your project and its tooling requirements. We try to include small engineering and design costs in the price of the tooling or even provide them at no charge. Smaller projects can cost less than $2,500 to get from design to engineering while larger projects with more demanding requirements can run up to $100,000. In order to provide a low-cost product with minimal setup and maximum quality and precision, we practice a seamless process to get the job done right the first time. The first step is to request a quote and discuss the product with an RSP sales rep. Once both parties agree that RSP is the best manufacturing partner for the project, an official order can be placed. This launches the design for manufacturing review, where we consider all the best practices of molding and design to optimize the model. After design suggestions are discussed, the engineering team at RSP can create a 3D model of the tooling. This 3D model will need to be approved by the customer before we proceed further, ensuring quality standards are being met every step of the way. During the tooling phase order, we provide weekly updates on tooling status, including photos. Get started today with the Get a Quote Button below.

10. In 99% of cases, the hard plastic part of the product is molded first, followed by the soft plastic part, primarily because soft plastic is more prone to deformation.

With the development of the injection molding industry, innovative techniques have emerged, pushing the boundaries of what’s possible in manufacturing. One such groundbreaking method is multi-shot injection molding. At Prototool, we’ve harnessed this advanced process, allowing for the creation of intricate and multi-material components in a single cycle. This offers unparalleled precision and design flexibility. In this article, we’ll delve into the nuances of this technique, shedding light on its benefits, design considerations, and its transformative potential in the realm of injection molding.

Dual-color molds typically consist of two parts. One half is fixed on the stationary platen of the dual-color injection molding machine, which is the side with the injection gate. The other half is mounted on the rotating platen, which is the side from which the mold ejects. Both molds’ rear cavities are usually identical, while the front ones differ. After the first material is injected into the first mold, the machine’s stationary and moving molds open. The rotating platen, carrying the rear parts of both molds, rotates 180 degrees. At this point, the semi-finished product from the first mold isn’t ejected. Instead, the molds close again, and the second material is injected. After cooling, the molds open, and the finished product from the first mold’s moving mold is ejected. This cycle produces one semi-finished and one finished product each time.

RSP offers high-quality custom plastic injection molding to bring your vision to life. Whether you need to create a fully functional prototype or require large volume production, we can make it happen.

RSP offers plastic injection molding services that work within a range of budgets. Many of our simple small single-cavity plastic injection molds cost between $1,000 and $6,000. Our average mold costs are $7,000-$9,000. Some very complex large tools run as much as $100,000 or more.

RSP has helped thousands of customers reduce product costs while offering them best-in-industry lead times. We have invested in automation and robotics to help drive down costs to save our customers money and improve quality. As a company, we maintain sufficient facilities and equipment that allow us to grow and manage capacity to keep consistent short lead times and still have the flexibility to respond to urgent requests.

As products became more intricate, the demand for tri-color and even quad-color molding began to rise. Generally, there are two types of tri-color machines: the two-station tri-color machine (colloquially known as the “pseudo tri-color”) and the three-station tri-color machine (known as the “true tri-color”). The distinction between the two isn’t about authenticity but rather the product structure design and the turntable control method adopted.

We take pride in our socially responsible and environmentally friendly facilities in the US and overseas. Our state-of-the-art plastic injection molding and assembly facility in China provides affordable tooling and molding while adhering to the United States’ manufacturing practices and quality standards. At RSP, we pride ourselves in doing our part while practicing sustainable manufacturing and utilizing eco-friendlier manufacturing materials.

RSP can provide stock mold or custom plastic injection services in 1000’s of materials including some of the most popular materials:

Hemp is a leading-choice fiber, as some of the largest car manufacturers are integrating it into their production. Beyond reduced environmental impact, there is good reason for choosing natural fibers: performance. Hemp-infused plastic, for example, can be up to 5 times stiffer and 2.5 times stronger than polypropylene (PP).

12. Provisions for venting during the first, second, or subsequent injections need to be thought out in advance to prevent defects and ensure quality.

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Dual-color and multi-color injection molding has become a focal point in the evolution of injection molding technology, and its benefits are manifold. Various techniques allow for different hardness and resilience within the same component. Soft plastics like TPE offer diverse color options, transparent surfaces, and other appealing features, enhancing aesthetic design. This method eliminates assembly steps, shortens the molding cycle, reduces processing costs, and offers added value to the end-users in terms of design, quality, and functionality.