Production of trial parts and prototypes: There are certain cases where you need more product samples and you can’t just fully rely on the 3D printing machine. When this is the case, you can rely on short run molding to produce more samples for you in less time. This is a lot better than using 3D machines for prototyping which can be greatly limited.

Short-run injection molding is used commonly for the production of high-quality goods. A lot of niche industries rely on this production process to create a low amount of products and accessories each year. It can be used in various ways such as:

Rooted in advanced moldmaking and driven by unparalleled precision molding expertise, nothing defines Micro Mold and Plastikos more than our people. With more RJG Master Molders and degreed Plastic Engineers than any other manufacturer our size–and a vast majority of larger resources as well–you’ll find a tight-knit, technologically advanced workplace that’s brimming with talented, motivated individuals. Committed to innovation, we bring together experts from various disciplines to deliver exceptional products, service and value on every project. It’s a mindset that extends throughout our entire organization and influences our approach as we cultivate future strategic partnerships.

At Plastikos, we are completely standardized on our precision molding equipment along with our auxiliary equipment (dryers, thermolators, hot runner controllers, and so on). All supporting equipment is directly tied into our molding machines, providing real-time data to our engineering and manufacturing team. This real-time data tracking is used detect a variation in any process variables, machine interruptions, and overall product yield for a specific production run.

We also utilize IQMS throughout our facility to optimize scheduling, production monitoring, and preventative mold maintenance. These combined industry 4.0 efforts have led to a remarkable 99% year-over-year on-time delivery.

We usually run into injection molded products in different stores at all times. Such products are often from big companies that make a high number of these products every year. Every year, they make use of injection mold technology to create a large volume of products. In some cases, they make millions of these products every year to be distributed across the world. This shows that this production model is suitable for large production runs. But what if you want to produce a new product in a few thousand or less? What if you want a low-volume on-demand production process that requires less time and costs? All of these objectives are possible when you use “short run plastic injection molding”. For many people, this is a relatively new process that comes with its advantages.

At Plastikos, our engineering and tooling team has developed our own proprietary mold maintenance program ranging from Level I – Level III. The various preventative maintenance levels are proactively scheduled based on the mold’s production volume, cycle count, and the abrasiveness of the raw material. As a result of our rigorous mold maintenance techniques, we have helped clients extend their mold life beyond 10 million cycles (and counting) in many cases.

Does not need any minimum order requirements: High-grade steel molds are used for larger production runs. However, if you are looking to produce several hundreds of certain materials, you don’t have to pay for a minimum amount of products. Simply use the short run injection molding process to mold as many products as you want. In this production system, you are not restricted by any volume requirements.

LEVEL I PREVENTATIVE MAINTENANCE This is level of PM is the most common and will be routinely scheduled during a mold’s production run. Minimal disassembly of the tool is required as we will perform a face cleaning of the cavity & core inserts and inspect for any premature wear.

For more about what is short-run injection molding as an industrial process,you can pay a visit to Djmolding at https://www.djmolding.com/low-volume-manufacturing-service/ for more info.

Used for producing limited edition cars and vehicles: Short-run injection molding is used extensively in the production of exotic cars. Many exotic cars are built in very few numbers. This is because it costs money and time to put them together. They are produced by using short run injection molding technology. This molding system can be used to ensure high quality as well as bespoke aesthetics.

In the medical industry: In a lot of cases, medical instruments are needed for specialized uses and will require a few hundred parts and accessories to be produced. It is perfect to use the short run molding for low production runs with high product quality.

We implement Arburg’s proprietary ALS system through our entire precision molding operation. This plant-wide system is used to store and upload a qualified process to any molding machine and virtually eliminate the chance for operator error during process set up. Key process variables can only be accessed (and changed) by a qualified process engineer, further reducing any chance for variation throughout production.

Scientific molding consists of sequential steps that are followed to establish nominal fill time, injection pressure, gate freeze time, pack pressure, cycle time, and clamp tonnage among other process variables. From there, key process parameters are often tested through the means of a Design of Experiment (DOE) to reach the process window that will be duplicated each production run.

Usefulness in the military and aerospace industries: The military and the aerospace industries are very similar to the medical industries. Unlike many fast-moving consumer goods (FMCG) industries, these industries do not always require a large volume of parts and products. In this case, they rely on short run molding to produce a limited number of accessories and parts.

Our team of degreed Plastics Engineers has completed rigorous training in scientific decoupled molding strategies through Penn State’s Plastic Engineering program. This specialized training is essential for successful process optimization and qualification.

Short run plastic injection molding is a production process that is also known as small batch or low-volume injection moulding. This production process requires reduced capital and a shorter time to develop. This molding system is used for the production of simple plastics through high-grade aluminium or low-grade steel injection molds. High-grade steel injection molds are used in large-volume plastic production runs. The short-run plastic injection molding is best suitable for injection molding production that needs less than 10,000 parts to be produced.

Our In-house Mold Maintenance Department is staffed with experienced toolmakers—ensuring the longevity of our customers’ injection molds and minimizing downtime due to repair and maintenance issues. All spare steel is assigned a custom detail number and cataloged in our ERP system which will notify us when we need to reorder certain spare cavity & core inserts.

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It helps to reduce the overall production time: Short-run injection molding helps increase the turnaround time of parts production by a matter of weeks or days. This usually depends on how complex the mold designs are. This is highly beneficial in comparison to high-grade steel molds which usually take months for production to be completed.

Plastikos & Plastikos medical operate around the clock to further minimize downtime / risk to our customer’s supply chain. Due to the extensive engineering & automation techniques, many of our high-volume molding machines can run completely light’s-out at night & weekends. All departments (QC, tool maintenance, material handling, etc.) are staffed to support this 24/7 schedule.

Produce goods of high quality: People often think that short run molding cuts corners and does not offer accurate dimensional tolerances as well as quality. However, the fact behind this production process is that it offers very high dimensional tolerances. It also provides excellent surface quality while also supporting high-volume injection molding processes. It offers exceptional quality when it comes to fitting different parts together.

Additionally, we highly recommend implementing each precision mold with cavity pressure sensors as a method to further detect any process variation within the cavity. Once a nominal cavity pressure has been established through the process development phase, a master file can be saved. During start-up production, this master file is uploaded and will provide 100% traceability through the production run. Any product that falls outside of the established process window will be automatically discarded at the press with the use of a 3-axis robot. All molding machines at Plastikos are equipped with this cavity pressure monitoring software and tied directly into our molding machines for real-time process monitoring.

Digitalizing a manufacturing operation remains at the forefront of Industry 4.0. The ability to gather real-time data has become essential when optimizing key elements such as product yields, machine efficiency, product quality, and overall profitability.

It can accommodate a wide range of material options: When it comes to resin options, there are no limits to using short-run molding. There are thousands of available resins that you can use for this production process. In addition, you can also apply the resins used for higher volume molding for this production process.

The chart below provides a comprehensive list of the precision injection molding equipment that we utilize at Plastikos. All departments are supported by our highly-trained team of processing, tooling, and quality control experts.

LEVEL II PREVENTATIVE MAINTENANCE This is level of PM will build on the first level and we will conduct a deeper dive into the tool. Partial disassembly of the tool will be required as we will lubricate the tool, clean vents, and further inspect for any wear or damage.

There are many short run injection molding companies around. However, you need to choose the best option. A reliable injection molding company will offer you all the benefits of this type of molding as we have highlighted above. Many such companies have a great deal of expertise in short-run projects. Additionally, these companies may offer similar production solutions with the use of 3D and CNC machines. This is because all these machines can be used for supporting or complementary services during an injection molding project. This is necessary because, in reality, many of these production systems are used to support each other. Then again, they are more suitable for specific projects that may not require the use of any other production technology. A reliable manufacturing company will provide the best short-run injection molding services. They will also help their customers solve the different problems as seen in short run injection molding systems. It is common to use a manufacturer that has completed thousands of injection molding projects for different customers.

Two white room molding centers with all-electric high-speed machines ranging from 66T – 220T. All molding machines are equipped with cavity-pressure monitoring software (eDART) and many outfitted with 3-axis robotics for part handling.

It calls for low initial costs: Higher-grade aluminium or lower-grade steel costs less when compared to that of the high-grade steel needed for large production runs. Certainly, high-grade steel can be used to produce thousands/millions of parts, but short-run injection molding is more suitable for low-volume production.

Process validation is a critical step in the development cycle before the mold & product can be deemed fit for production. During this process, scientific molding principles should be applied to establish the nominal running conditions for that given mold, material, etc.

Djmolding is plastic injection mold maker in china,as a china plastic injection molding manufacturer supplier factory,we supplying high-precision plastic injection products,low volume injection molding for low volume manufacturing service,high volume injection molding,quick-turn injection molded parts and so on.

Huizhou Djmolding Co., Ltd, established in 2010, is a leading plastic injection moulding and mould manufacturer in China. Djmolding is a low volume manufacturing companies specializes in plastic mould and plastic parts production for household appliances, medical equipments, electronic equipments, safety equipments as well as monitoring system.

Our team of degreed Plastics Engineers has completed rigorous training in scientific decoupled molding strategies through Penn State’s Plastic Engineering program along with RJG’s Master Molder program. This specialized training is essential for successful process optimization and qualification.

LEVEL III PREVENTATIVE MAINTENANCE This is level of PM requires full disassembly of the tool and is scheduled off the mold’s cycle count and production volume. Wear items will be replaced, as needed. Water lines are fully cleaned to prevent scaling and manifolds will be serviced, where applicable.

Industry 4.0 strategies have been implemented plant-wide to provide enhanced data sharing and traceability among molding machinery. This proprietary system ensures only our process engineers can adjust process parameters, which minimizes manual error during production startup.