At Sussex IM, we strive to solve our customers’ problems in the most efficient way possible. Backed by our proven injection molding expertise, one of the ways that we deliver solutions is through two-shot or multi-shot injection molding. As your injection molding experts, Sussex IM is always looking for new ways to address our customers’ needs. To maintain this responsibility, we have continued to expand our medical injection molding capabilities with the addition of our new Class 8 clean room.

Plastic is an excellent material for producing toys since it lacks many of the limitations that other materials possess (wood splinters, metal rusts, cardboard is weak, none of those is suitable for babies who put toys in their mouths). Plastic, on the other hand, can stand on its own. Plastic may be used to:

Thermoplastics are the most common toy plastics. They are heated and softened before being formed by applying pressure on them in a mold or die. The plastic soon cools and hardens.

The necessary double injection is carried out on one machine, built and programmed to perform two injections in one cycle. While the process can also occur with two or more molds in multiple injection molding machines, using one mold and one injection molding machine ensures reduced handling and guaranteed cleanliness. The single press method is also the lowest cost.

This versatile manufacturing process produces complicated molded parts that may have different colors, components or materials. Usually, those factors are limited to two different types, but with customization of the molding machine and mold construction, a part could utilize up to three materials. Additionally, the use of multiple injection molding machines can create an even larger combination of materials.

If you have a sales inquiry, an RFQ / RFP or if you have any questions, please fill out the form below or email us directly at contactus@sussexim.com

ACIS®, Autodesk Inventor®, CATIA® V5,Creo™ Parametric, IGES, Parasolid®, Pro/ENGINEER®,Siemens PLM Software’s NX™, SolidEdge®, SolidWorks®, STEP

Beyond the ability to seamlessly create multi-color or multi-material parts, two-shot injection molding also is a flexible process that allows for added creativity and complexity in part design, opening up part complexity possibilities. The unique capabilities of two-shot injection molding are especially beneficial for the medical market as medical device designs continue to advance and have become increasingly intricate.

Artwork – There are several ways to produce artwork. If you are not a professional artist or designer, locate a toy broker who can make the artwork for you, as any two-dimensional art must be precisely reproduced onto a three-dimensional figure. If you are a designer who works in Adobe Illustrator, it is critical to plan your artwork so that it can be quickly adapted to a physical model. You should also be familiar with how art is done, as designs may be put to your toy using a variety of ways ranging from paint to decals or tape. A lot depends on how detailed you want the finished item to be.

When examining the end-use, it is vital to understand if the device will require higher durability, protecting against being exposed to fluctuating temperatures and the resilience required. For medical applications, considerations of FDA regulations the product will need to meet, especially if the device will be inserted into the human body or in contact with bodily fluids, will be critical.

Injection molding is a technique for producing high-quality three-dimensional items that can be mass-produced. High volume injection molding production necessitates Class 101 molds, a hot nozzle, and an automated production design to save molding costs. If you opt to use recycled plastic material, be mindful of the density and strength it may affect. Toy parts must always have a colorful look; thus, the color powder mix ratio and injection molding manufacturers must set parameters, the color of each batch part will deviate beyond acceptable limits.

Many parents are worried about providing safe plastic toys for their young children. Others are concerned that plastic toys may harm the environment. Fortunately, new plastics advances have enabled manufacturers to create safer, more environmentally friendly toys.

Material — Our team was shocked by the restricted number of materials available, but it is critical to investigate your alternatives because materials may determine the adaptability of your item.

To enhance all of our injection molding expertise, Sussex IM has complete service offerings including, design for manufacture, dedicated 3PL capabilities and inventory management to round out our full-solutions service. From start to finish, we are the comprehensive partner to ensure success – that’s the Sussex Solution.

Material selection is always complicated, and given the recent shortages and price increases, finding your first choice can be nearly impossible, meaning material replacement is a growing need. At Sussex IM, our knowledgeable team is happy to help guide you through the material selection process.

With the combination of different properties into one part, two-shot injection molding also provides value through improved aesthetics, functionality and quality. While any market will enjoy the benefits of combining materials to improve part integrity and greater visual appeal, as this process improves color and eliminates painting in secondary operations, the medical market has several applications where this manufacturing process is unmatched.

Quantity – The optimum material to utilize (mold making) and project timeline will be determined by the quantity of your toy. You could wish to order 2,000 miniatures in advance and have them painted as various personalities in batches of 500. Alternatively, you may simply require 100 figurines in total. Each choice has distinct outcomes, methods, and prices. Consult with your vendor to find the best technique for your specific requirements.

Toy molds in their processing features and processing technologies are also more difficult and specific than other molds, based on the aforementioned toy product design and plastic mould design needs. To ensure this, it must use specialized processing technologies. For instance:

Sussex IM is a family owned, custom injection molder centrally located in Sussex, Wisconsin. Proud of our Midwestern roots we pride ourselves on providing solutions to meet our customers needs. We look forward to hearing from you.

Plastic toys dominate the toy industry, and practically all plastic molding technologies are used in their manufacturing. The following are the most popular types of plastic toy molds:

In this article, we will discuss the different types of plastic toys, materials used in plastic toy production, things to consider when designing plastic toys and how to make plastic toys yourself. Let’s get started.

A quick stroll down any store’s toy aisle will reveal that the vast majority of toys on the market today are made of plastic. Plastic’s moldability, lightweight, colorfulness, and strength have made it the go-to material for modern toy creation, from building blocks to robots, gaming pieces, figurines, and model vehicles.

Shape and Style – It is advisable to consider all of your possibilities. To assist establish the final aesthetic, our team analyzed different toys both in-person and online. It is also beneficial to create a variety of forms and sizes and then collaborate with your provider to pick the finest solution. If you begin with a character in mind, consider constructing a 3D representation of yourself to guarantee your vision can be recreated.

For example, a medical device housing would require a material that is both durable and aesthetically pleasing. Two-shot injection molding can also offer an end-product that features a rigid plastic housing with a soft-touch grip.

As the case with any manufacturing process, material selection is a critical part. In multi-shot injection molding, the selection process becomes even more vital as the resin not only has to be a fit for the end-use application, but the materials have to be a fit, chemically, with each other. Otherwise, bonding will not occur. Another way to overcome this challenge is through part design, mechanically bonding the two materials via internal channels and interlocking features. Typically, to aid in this decision-making process, a material compatibility chart is available to determine which resins may work together for this particular kind of injection molding.

Step 2: Melting- There will most likely be a dip in the center of the form, so put some additional beads there. Put another sheet of plastic paper on top and iron it, careful to maintain the plastic inform when you raise the iron. Submerge in chilly water. Check the form, and if it’s not melted enough (which it frequently isn’t), return it to the ironing board and iron some more!

If you have a medical device application, multi-shot injection molding can benefit your needs and the advantages this manufacturing capability provides.

Plastic injection molding has had a significant influence on the toy business, and toy industry inventions have fuelled advancements in injection molding, such as multicolor plastic injection molding. Immould has the knowledge and skills to turn your molded plastic toys and parts into a reality. Contact us now to see how we can work together to shape the future of play.

There are six things we learned when designing a bespoke toy that will help you save time and money while also making your ideal toy a reality.

Step 1: Begin by melting a color or colors of beads for your form. I built a bone and some fish, both of which were approximately an inch long. Fill the mold halfway with beads to determine the correct amount. Then, place them standing up on one piece of parchment paper, then gently place another on top. Iron these until they are completely flat. It’s helpful to have your mold nearby since you’ll need to swiftly peel off the melted beads and push them into the mold. It doesn’t have to fit precisely. As soon as you press it in, it will take on the form and you will melt it more.

Rotational molding is used to make toys, transport drums, storage tanks, and consumer furniture. Each piece is created by covering a mold from the inside out. Between two mechanical arms, a mold is kept in position. The arms then continuously spin the mold at the same level as molten plastic is put inside. The plastic coats the interior of the mold as it rotates, creating a new hollow, plastic item.

There are numerous benefits of multi-shot injection molding. Providing the simplest and most cost-effective way to produce parts with multiple materials, as the process only requires one machine cycle, multi-shot injection molding delivers reduced costs and needs for labor. The efficient process will also produce higher output levels compared to other manufacturing processes.

Mold Type – Choosing a material for your figure will help you select what material you may use for your mold. We had two choices: silicone or metal. After weighing the benefits and drawbacks of each, we decided on a silicone mold for our resin figure to help keep costs down. Silicon molds need to be replaced after 30 to 50 usage. Metal molds stay forever and are an investment when doing rotocast vinyl, but if you plan on making a lot of toys, this is the best way to go.

At Sussex IM, we recognize the nuances necessary for medical injection molding. To continuously serve the increased demand for medical manufacturing and new product development, we have strengthened our capabilities to support medical injection molding with our ISO Class 8 clean room.

Prototypes or test pulls – These prototypes or test pulls will serve as benchmarks for how the toy project progresses. Your first test pull will happen early in the tooling process when you’re establishing how the figure should appear. This is significant because whatever is authorized at this point will initiate the initial stages in casting your official toy mold. Following the casting of the mold, your final artwork will be transferred to a sample pull for evaluation. Again, your toy broker must have an excellent relationship with manufacturing facilities since any modifications to the artwork at this point must be carefully conveyed.

With the recent increased demand for medical products, multi-shot injection molding is as popular as ever. The multi-shot injection molding manufacturing technique offers several favorable qualities that appeal to the medical market including, the opportunity for increased sterilization, molding precision and cycle time.

Two-shot, or multi-shot injection molding, is a highly efficient manufacturing process in which molded parts from two or more different materials are combined to build a single product.

The design, manufacture, and processing of plastic toy molds are crucial to the success and difficulties of toy production. Toy molds are more varied, complex, and mixed than other types of molds. It comprises both plastic and metal toy molds.

If you have a sales inquiry, an RFQ / RFP or if you have any questions, please fill out the form below or email us directly at contactus@sussexim.com