Locator Ring: Metal ring that ensures the nozzle of the injection-molding machine interfaces properly with the sprue bushing.

Overmolding – This injection molding method is used to create parts made with two different types of plastic. A good example of this would be a portable drill body or game controller with a hard outer shell with soft, rubberized grips. A previously molded part is re-inserted into a specially made mold. The mold is closed and a second layer of different plastic is added over the original part. This is an ideal process when two different textures are desired.

Cooling System: A series of channels in the outer shell of the mold. These channels circulate a fluid to aid the cooling process. Improperly cooled parts may display a variety of surface or structural defects. The cooling process typically makes up the majority of the injection molding cycle. Reducing cooling times can significantly improve mold efficiency and lower cost. Fathom offers Conformal Cooling for many injection-molding applications that will increase mold efficiency up to 60%

Injection Mold Components Most injection molds are made up of two parts – an A side and a B side, or the cavity and the core. The cavity side is typically the best side while the other half, the core, will have some visual imperfections from the ejector pins that push the finished part out of the mold. An injection mold will also include support plates, ejector box, ejector bar, ejector pins, ejector plates, sprue bushing, and a locating ring.

Runner or Runner System: Channels within the metal mold that allow molten resin to flow from sprue-to-cavity or cavity-to-cavity.

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Mold Frame or Mold Base: A series of steel plates that holds the mold components together, including cavities, cores, runner system, cooling system, and ejection system.

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Injection molding is a manufacturing process with a lot of moving pieces. Below are a list of terms that describe many of the pieces necessary for mold production and injection molding. The tooling consists of several steel plates within a frame. The mold frame is placed into the injection-molding machine and held in place with clamps. A cut away of an injection mold viewed from the side would resemble a sandwich with many different layer. Check out our Injection Molding Glossary for a full list of terms.

B Plate: The other half of the metal mold. The plate contains moving parts or space to allow moving parts to interact with the finished part – typically the ejector pins.

After mold production, the next step is to select the proper plastic material. Material selection will depend on the how the final part will be used. Plastic materials have a variety of characteristics to consider. This includes over all appearance and feel, as well as resistance to chemicals, heat, and abrasion. Speak with the experts at DJmolding to learn more about available plastic materials for injection molding.

Since 1955, Custom Plastics, Inc. has been the go-to plastic extrusion and injection molding company in the Midwest. As a privately-owned and operated business, we take pride in our extensive expertise and dedication to keeping up with the latest advancements in plastic engineering, extrusion, and injection molding.

Gate: The end of a runner where the melted resin enters the mold cavity. There are different gate designs for different application. Commonly used gate types include pin, spoke, fan, edge, disk, fan, tunnel, banana or cashew, and chisel. Gate design and placement are important considerations before starting the mold manufacturing process.

Ceramic Injection – Injection molding process utilizing ceramic material. Ceramic is a naturally hard, chemically inert material that is used in a variety of industries. Ceramic injection requires several extra steps; including sintering or curing the newly molded parts to ensure the characteristic durability.

Plastics are a material commonly used for products across a variety of industries. Toys, automotive components, medical devices, tools, and more are all made from plastic. Many of the plastic items or we encounter in our every-day-lives are produced by manipulating melted resin into a specified design with manufacturing process called plastic injection molding. This highly efficient process can make parts in many sizes and shapes and can replicate the same part multiple times using the same mold. At the heart of this process is the mold, also known as tooling. A high-quality mold manufacturing process is essential to producing quality parts while maintaining a cost effective performance. Part quality will go up and overall project costs will go down when investing in high quality mold manufacturing.

We collaborate with Original Equipment Manufacturers (OEMs) across multiple industries on a global scale to manufacture plastic parts and assemblies that not only reduce the overall cost of production, but also streamline the assembly and manufacturing process, and enhance end products with our value-added finishing services.

Cavity or Die Cavity: Concave impression in mold, usually forming the outer surface of the molded part. Molds are designated as single cavity or multi-cavity depending on the number of such depressions.

Ejector Pins: Steel pins that contact the finished part and push it out of the mold. Ejector pin marks are visible on some injection-molded items, typically a round imprint found on the back of the part.

Ejector Plates: A steel plate that contains the ejector bar. The ejector plate moves to eject the finished product after molding.

At Custom Plastic Inc., we have a strong commitment to manufacturing top-notch plastic parts. Our dedicated team of experts in quality control verifies that your products meet exceptional standards prior to their shipment from our facility. We collaborate with our clients to establish effective quality assurance measures that guarantee exceptional quality in every production cycle.

Thin-Wall Molding – A form of injection molding that focuses on shorter cycle times and higher productivity to produce thin, light, and cheap plastic parts.

Insert Molding – An injection molding process that allows for the incorporation of metal, ceramic, or plastic pieces into the final part. The metal or ceramic parts are placed in the mold and then melted plastic is injected into the mold to create a seamless piece made of two different materials. Insert molding is ideal for automotive applications as it is an innovative way to reduce weight and reduce costly material like metal. Instead of making the entire piece out of metal, only the connecting pieces need to be metal while the rest of the item will be made out of plastic.

Core: Convex impression in the mold, usually forming the inner surface of the molded part. This is a raised portion of the mold. It is the inverse of the cavity. Molten resin is always pushed into the cavity, filling the space. The molten resin will form around the raised core.

Starting with the acquisition of a single extrusion machine, Custom Plastics, Inc. has come a long way since 1955. From one production line, we have expanded to operate 20 extruders. With our extensive knowledge and proficiency, we can manufacture and deliver high-quality components punctually and consistently.

Sprue Bushing: The connecting piece between the mold and the injection-molding machine where the molten resin will enter the cavity.

Low-Pressure Plastic Injection Molding – Plastic parts that are produced at lower pressures. This is particularly useful for jobs that require an encapsulation of delicate parts, such as electronics.

Co-Injection Molding – Two different polymers are sequentially or concurrently injected into a cavity. This process can be used to create parts with a skin of one kind of plastic with the core of another.

At Custom Plastics, we have earned the trust of our industry peers by offering unparalleled customer service, maintaining industry-leading quality assurance standards, and maintaining an on-time delivery rate of more than 98%

Contact DJmolding for more information on plastic injection molding. Our team of experts can assist you with your plastic injection molded project.

The selected material begins as a plastic pellet that is fed into a hopper on the injection-molding machine. The pellets make their way through a heated chamber where they are melted, compressed, and then injected into the mold cavity. Once the part cools, the two halves of the mold open to eject the part. The machine then resets to begin the process again.

Rubber Injection – Rubber is injected into a mold using a process similar to plastic injection molding. Rubber parts require more pressure for successful injection molding.

Injection Molding Process Steps Injection molding is one of the most common manufacturing processes used to produce plastic goods. It is a high-demand process that can reproduce the same part thousands of times. The process starts with a Computer Aided Design (CAD) file that contains a digital copy of the part. The CAD file is then used as a set of instructions to aid in the mold manufacturing process. The mold, or tool, is typically made from two pieces of metal. A cavity in the shape of the part is cut into each side of the mold. This mold is usually made from aluminum, steel, or an alloy.

Our all-in-one facility can help you save both time and money. From design and prototyping to assembly, printing, packaging, inventory management, and shipping, we offer a comprehensive range of services under one roof. Rather than searching for components and services around the globe to complete your product, you can keep it local and let us handle everything for you. With our one-stop shop, you can streamline your production process and focus on other important aspects of your business.

Multi-Cavity or Family Mold – This mold has multiple cavities in a single mold frame that produce several of the same or related parts with each injection cycle. This is an ideal way to increase run volumes and lower the per-piece-price.

DJmolding mould Manufacturing for Different Molding Processes The plastic injection molding process can be adjusted to accommodate different and complex needs. While it is ideal for manufacturing large volumes of simple plastic parts, it can also be used to create incredibly intricate parts with complex geometries or assemblies.

In 1975, Custom Plastics acquired its inaugural injection molding machine, which marked the beginning of our foray into this technology. From then on, our team has remained dedicated to delivering injection molded parts of unparalleled quality at competitive prices. In our quest to enhance our capabilities, we are continuously incorporating cutting-edge equipment and advanced processes.

What Material is used for Making Molds? Mold production is done with steel, aluminum, or an alloy. DJmolding uses high-quality steel for mold manufacturing. Steel mold production is slightly more expensive than using aluminum or an alloy. The higher cost is typically offset by a much longer life span for steel molds. Aluminum molds, while cheaper to produce, do not last as long as steel and must be replaced frequently. Steel molds will typically last well over one hundred thousand cycles. Aluminum molds will need replacement much more frequently. Steel mold production can yield highly complex designs not achievable with aluminum. Steel molds can also be repaired or modified with welding. Aluminum molds will need to be machined from scratch if the mold is damaged or to accommodate changes. High-quality steel molds can be used thousands, hundreds of thousands, and sometimes up to a million cycles.