Urethane casting uses silicone molds to create plastic prototypes with a high level of detail. It’s typically used during later prototyping stages when a design is more mature, and is a cost-effective way to produce 10 to 100 units for EVT. When a large number of prototype units is needed, urethane casting generally has lower per-piece costs than 3D printing.

Tessy Plastics’ success is based on its advanced technological capabilities and innovative approach to manufacturing. The company uses state-of-the-art automation and robotics. This enhances precision and efficiency in its manufacturing processes. Additionally, Tessy Plastics has a deep understanding of materials science and engineering. This technological edge allows Tessy Plastics to deliver superior products that meet the changing needs of its customers.

We exist to eliminate bottlenecks in new product development by integrating the people, processes, and platform you need to source custom parts.

Specializing in precision and efficiency, Decatur Mold leverages cutting-edge technology and innovative processes to deliver high-quality products that meet the exacting standards of their diverse clientele. Their expertise in tooling and design ensures that each project is tailored to the specific needs of customers, resulting in superior manufacturing outcomes. By integrating all aspects of the production process, Decatur Mold not only enhances product consistency and reliability but also reduces time-to-market and overall costs, making them a preferred partner for businesses seeking robust plastic injection molding solutions.

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MGS is a leader in custom molding of plastic parts. This is exemplified by their capability of executing complex designs, accurate measurements, and tough material specifications. Their latest machines are of injection molding type, from 28 to 1,500 tons. This enables them to do small-scale, large-scale, or complex projects.

USA Injection Molding was established in 2000. The company is based in St. Louis, Missouri. It has become a leader in the field of injection molding. USA Injection Molding specializes in many services, including tooling, design, assembly, and packaging. The company is proud to support a wide range of customers from different industries, such as automotive, consumer electronics, and medical devices.

ACO Mold is a top plastic injection molding company which is concentrated on the high-precision, complex parts for the demanding industries. Having over two decades of experience, ACO Mold has acquired a reputation for their expertise in mold design, tooling, and custom plastic molding with a massive manufacturing capacity, producing 300 mold sets a year and using over 30 different types of plastic materials such as ABS, polypropylene, nylon, polyethylene and more. The company has a vast variety of injection molding machines, from 80 to 650 tons, thus, they can meet the different market demands.

Collectively, the four plastic prototyping methods support a wide range of plastic resin materials. As the table below shows, however, there are differences in what each method supports. Some plastic prototyping processes don’t support some materials, while others support a much wider range of plastic resins, including glass-filled compounds.

Finally, these 11 leading plastic injection molding companies in the US have proven that they are highly competent, dependable and ready to offer superior custom plastic molding solutions. Each of these injection molding manufacturers has a unique set of abilities, experience and specialties which, in turn, will help you to identify the best partner for your specific needs.

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Create high quality custom mechanicals with precision and accuracy.

The company has over 100 skilled professionals. Each one is dedicated to maintaining the highest standards of quality and innovation, consistently delivering excellence in their plastic injection molding services. This commitment can be seen in their significant investments in the latest machinery and ongoing research & development efforts. These investments allow USA Injection Molding to stay up-to-date with technological trends and continuously improve their processes and products.

MGS Mfg. Group is an internationally recognized plastic injection molding company. They pay attention to innovations, sustainability, and customer satisfaction. MGS has more than one premise in the USA and Mexico. They provide complete manufacture services to a wide range of industries.

The company has its own tooling department in house. It works with the latest CAD/CAM software and CNC machining technology. This enables them to make strong molds that are of good quality and that have a long lifespan. An expert MGS engineering and designing staff who work together with customers are available. They focus on design optimization for manufacturability, function, and aesthetics. MGS provides not only plastic injection molding, but also automation solutions, assembly service, and supply chain management. Through provision of these services, MGS provides a comprehensive solution for their customers.

The worldwide plastic injection molding market is expanding fast. It is anticipated to grow to a size of USD 345. 1 billion by 2024, according to a report by Grand View Research, Inc. The growth is happening because there is a growing demand for plastic parts in various industries. These sectors are automotive, healthcare, consumer goods, and electronics. The businesses, in their search for the most reliable and efficient manufacturing solutions, need the experienced and capable plastic injection molding companies more than ever before.

The engineers and designers of Jabil that have a lot of experience work together with the clients. They assist in the improvement of product designs which, in turn, leads to the enhancement of the manufacturing process and the reduction of the costs. Jabil provides numerous materials to satisfy different requirements. These materials comprise of thermoplastics, thermosets, and elastomers. Jabil has offices around the world and a solid supply chain. Thus, they are able to deliver products on time with the same quality all the time. With their extensive technical and design capabilities, it’s no wonder why many major brands around the globe choose to collaborate with Jabil.

EVCO’s expertise in custom plastic molding is clear. They can handle complex shapes, precise measurements, and difficult material requirements. Their modern facilities have injection molding machines ranging from 28 to 3,500 tons. This means they can take on projects of various sizes and complexities.

Plastic injection molding is associated with high-volume parts production, but it can also support high-resolution prototyping. That’s because Fictiv can rapidly and cost-effectively produce steel molds for PVT, the last stage of testing before production. There are no minimum order quantities, and steel injection molds can achieve tighter tolerances than aluminum molds. T1 samples, the first part samples produced from the production tool, are available in as fast as 10 days.

EVCO Plastics is a family-owned plastic injection molding company. They have over 50 years of experience providing innovative solutions for many different industries. EVCO has multiple facilities in the United States, Mexico, and China. This allows them to offer global manufacturing capabilities. At the same time, they maintain a strong commitment to quality and customer service.

ACO Mold has been involved in more than 1000 innovative projects, from the idea to the full-scale production, which shows their deep knowledge of the market trends and their unconditional commitment to customer success. The company puts a lot of importance on material advantage, it only deals with certified resin suppliers and reputable steel brands to guarantee the best component quality.

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In this article, we will discuss the 11 best plastic injection molding companies in the United States. We picked these companies on the basis of their good reputation, experience, and the services they offer. We will provide a summary of each company and emphasize their distinctive strengths, capabilities, and the industries they belong to. Through the article on these injection molding manufacturers, readers will acquire important knowledge about the industry. They will also be able to select the suitable partner for their custom plastic molding requirements.

Moreover, USA Injection Molding is excellent at providing complete solutions that cover the entire production process, from initial design to final product assembly. This comprehensive approach ensures that each project is customized to meet specific client needs. It also improves efficiency and cost-effectiveness. USA Injection Molding focuses on sustainable practices and customer satisfaction. As a result, the company is a leader not only in technological advancement but also in customer loyalty and industry respect.

In this highly competitive market, injection molding manufacturers in the United States are the ones that are making it. They have a large number of services, cutting-edge technologies, and a team of experts with specialized skills. These companies can deal with projects of different complexities and sizes. They can do the fast prototyping and the high-volume production runs. They employ advanced technology, skilled workers, and innovative processes. Thus, it enables businesses to get their products to the market sooner, more efficiently, and with better quality.

Furthermore, Tessy Plastics is dedicated to sustainability and environmental responsibility. The company has strategic waste management and recycling initiatives. These initiatives help minimize its environmental impact while the company continues to expand its market reach and improve its services. Tessy Plastics’ commitment to quality, innovation, and sustainability makes it a leader in the plastic injection molding sector.

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3D printing (3DP) plastic is a form of additive manufacturing that supports rapid prototyping and multiple iterations. Fictiv offers a range of 3DP technologies, each of which can be used for specific types of prototypes:

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Every one of these companies has a good reputation of offering the customers with the plastic injection molding solutions that are reliable and efficient in different industries. They provide a variety of services, from design and prototyping to full-scale production and assembly, which are all the needs of their clients.

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If you need a prototype that uses the same material as the end-use product, review the chart above with care. For example, both CNC machining and injection molding support ABS; however, 3D printing and urethane casting support an ABS-like material instead. This ABS-like material is not identical to ABS in terms of end-use properties and, consequently, might not meet your testing requirements.

These four manufacturing methods are not mutually exclusive, nor do you have to use all of them. For example, you could use 3D printing for rapid form factor prototyping and injection molding for high-resolution prototyping. Along the way, Fictiv can provide the design for manufacturing (DFM) feedback that you need to refine your designs.

Customers can use the Xometry’s online platform that is very easy to use to upload their 3D designs. Besides, they can also select the materials and finishes, and get the instant quotes. Xometry has a vast network of trustworthy injection molding manufacturers. Thus, projects are paired with the best partner who has the skills, capacity, and expertise that fit the project. Xometry also offers shipping services for completed projects, with customers responsible for any associated shipping and packaging costs.

Protolabs Network is a worldwide top in the rapid prototyping and on-demand production services, among which plastic injection molding is one of them. Through their vast network of facilities in North America and Europe, Protolabs provides quick, dependable, and cost-efficient solutions for businesses of all sizes.

Protolabs provides a broad spectrum of materials, for example, commodity and engineering-grade plastics, as well as liquid silicone rubber (LSR) for specialized applications. The experienced team of engineers of this company is the one who gives the customers the expert guidance and support during the whole product development process, thus helping the customers to optimize the designs for the functionality, manufacturability and the cost-effectiveness.

Jabil does not only custom plastic molding, but it also does more. Besides, they also offer other services such as product assembly, testing, and packaging. The company is constantly coming up with new ideas and enhancing its products. Thus, Jabil has become a highly respected company in the plastic injection molding industry.

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There’s plenty to consider if you want to create the perfect plastic prototype, but Fictiv is ready to help. Fictiv is your operating system for custom manufacturing that makes prototype part procurement faster, easier, and more efficient. We support all of the above plastic prototyping methods, and the end result is you building better products, faster,  no matter which type of prototype you need.

The company has an in-house tooling department. It uses advanced CAD/CAM software and CNC machining technology. This allows them to produce high-quality, long-lasting molds. EVCO’s experienced team of engineers and designers work closely with customers. They optimize product designs for manufacturing, functionality, and appearance. In addition to plastic injection molding, EVCO offers additional services. These include assembly, packaging, and logistics. By providing these services, EVCO offers a complete solution for their clients.

Jabil Inc. is a worldwide manufacturing company which is specialized in plastic injection molding. The company has been in existence for over 50 years. In this period, Jabil has become a reliable partner for many different industries. The modern facilities of Jabil have the most up-to-date technology. This way they can easily cope with complicated designs and big production runs.

Whether you need rapid prototyping, mass production, or any particular materials, these companies have the expertise, equipment, and commitment to help your projects become a reality. Working together with one of the top plastic injection molding firms, you will have an advantage of their professionalism, latest facilities and customer satisfaction, hence your products will be successful in the market.

Hi-Tech Mold & Engineering is a leading plastic injection molding company that focuses on servicing the automotive, medical, aerospace, and military sectors. Almost 40 years of experience has made Hi-Tech Mold a known name for their mastery in mold design, tooling, and custom plastic molding.

Our trained employees ensure your parts will be delivered on time and to spec.

Remember that plastic prototyping is a good method for testing a design and provides valuable information during the design process — it helps eliminate errors and identify risks before production or work on the next prototype iteration begins.

The silicone molds that are used in urethane casting cost less than aluminum or steel injection molds; however, each silicone mold can produce only a small number of parts. Because these silicone molds must be replaced after 20 to 25 units, this limits the value of urethane casting as volume increases.

Yomura Technologies, Inc., established in 1989 and based in Fremont, California, has carved out a niche in the competitive field of plastic injection molding. With over 200 employees, the company specializes in injection molding, tooling, design, assembly, and packaging, offering comprehensive solutions tailored to the needs of industries such as telecommunications, automotive, and consumer electronics.

ACO Mold’s full-fledged mold validation procedures, which include CMM reports, cooling line testing, and CPK reports, assure the flawless operation and the best product quality, thus, they are the most respected innovators in the injection molding services industry.

The company’s proficiency in complex, precision-engineered parts sets it apart in the industry. Yomura Technologies employs advanced injection molding techniques and utilizes high-performance materials to ensure durability and functionality in its products. This focus on high-quality outputs, coupled with rapid prototyping capabilities, allows Yomura to quickly adapt to market changes and client demands.

Plastic prototyping creates a preliminary version of a plastic part or product. Depending on your design’s maturity, a prototype can look like and/or work like the expected end-use version. Looks-like prototypes are also known as models. They’re more advanced than mockups, but lack the functionality of works-like prototypes, which improve with each iteration as a design reaches greater levels of maturity.

Tessy Plastics Corp. was founded in 1973. The company is based in Skaneateles, New York. It is a well-known player in the plastic injection molding industry. Tessy Plastics has over 1,000 employees. The company offers a wide range of services, including injection molding, tooling, design, assembly, and packaging. Tessy Plastics serves many different markets, such as medical, consumer products, and electronics. The company emphasizes a commitment to high-quality production and customer satisfaction.

Xometry is the leading online manufacturing platform. It links businesses with a network of plastic injection molding companies and other manufacturing services. Xometry’s innovative approach simplifies the buying process. This in turn, simplifies the process for customers to get the best custom plastic molding solutions.

When it’s time to select a plastic prototyping method, consider both the type of prototype and the tests you’ll perform in addition to speed, part tolerances, resolution, and cost considerations.

Are you ready to create the perfect plastic prototype? You’ll probably need more than one type of prototype during the design process, which means choosing between various plastic prototyping methods and materials. Some techniques don’t support certain plastics, however, and they each offer different prototyping speeds, part tolerances, resolution, and cost.

Furthermore, Yomura Technologies is committed to innovation in both its processes and products. By continually investing in cutting-edge technology and skilled personnel, Yomura maintains its competitive advantage and leads in delivering efficient, sustainable solutions that meet the stringent standards of its global clientele.

CNC machining plastic uses computer-controlled machine tools to remove material from a pre-formed shape. It’s faster and more accurate than manual machining and can achieve greater geometric complexity. Precision machining tolerances vary, so you should ask about  achievable tolerances prior to starting a new project. Typically, CNC equipment is used to produce mid-stage functional prototypes, and specific services include CNC milling, CNC turning, and gear hobbing.

Decatur Mold, founded in 1966 and based in North Vernon, Indiana, is a premier provider of comprehensive plastic injection molding solutions. With over 200 skilled employees, Decatur Mold offers a full suite of services including injection molding, tooling, design, and assembly. The company’s extensive experience and commitment to quality have established it as a leader in the industry.

The digital manufacturing of the company enables customers to upload 3D CAD models, choose the materials and finishes, and get the instant quotes and the design for manufacturability (DFM) feedback. The automated quoting system and the advanced manufacturing processes of Protolabs allow them to produce the high-quality custom plastic molding parts with lead times as short as one day.

Ficitv is the perfect partner for manufacturing your perfect plastic prototype. And our innovative digital manufacturing ecosystem can scale from your plastic prototypes to scaled production, with industry-leading speeds every step of the way.

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In the subsequent, we will discuss each company in more detail. We will emphasize their special qualities and benefits, and also the kind of services they provide. Besides, we will also look into the factors that have made them the top players in the plastic injection molding industry.

Accelerate development with instant quotes, expert DFM, and automated production updates.

We exist to eliminate bottlenecks in new product development by integrating the people, processes, and platform you need to source custom parts.

Xometry has the rigorous quality control measures and is determined to satisfy the customers. As a result, businesses of all sizes rely on Xometry. The company has a wide range of materials, for instance, the common and the engineering-grade plastics. Besides, they also have specialized polymers for unique applications. Through Xometry, customers get quick delivery, low prices, and good service throughout the whole manufacturing process.

The company’s latest production facilities are furnished with modern injection molding machines that can work with a wide range of materials such as high-performance engineering plastics and medical-grade resins up to 1,000 tons. Hi-Tech Mold’s skilled team of engineers and technicians have the latest CAD/CAM software and simulation tools at their disposal and that is how they can optimize mold designs and achieve uniformly high-quality results.

The table above displays the 11 of the best plastic injection molding companies in the United States that are now the market leaders in 2024. The companies were chosen according to several important factors. The first is their skill in managing the complicated designs and the large-scale production. The second is their incorporation of the latest technology and the development of new processes. The third is their dedication to customer satisfaction, which is achieved by providing top-notch products and services.

They are able to fully control the production of the molds by their in-house tooling department that designs high-precision, durable molds, including plastic injection molds, to meet the most stringent requirements. Along with plastic injection molding, Hi-Tech Mold introduces rapid prototyping services that not only aid in design validation but also make it possible for customers to make appropriate changes before the production commences.