ABS has a relatively low melting point that makes it easy to mold. This opaque polymer supports the use of colorants as well as various textures and surface finishes. Its butadiene content delivers exceptional toughness, even at low temperatures, and its styrene content imparts a shiny, attractive finish to plastic injection molded parts.

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Two-Shot Injection Molding: Requires materials that are compatible with each other and capable of adhering together during the molding process. Some materials may require pre-treatment or special bonding agents to ensure proper adhesion.

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TPE is a blend of plastic and rubber materials. It is processed like plastic but has the properties and performance of rubber. Known also as thermoplastic rubber (TPR), TPE can be stretched to moderate elongations and, upon the removal of this stress, returns to the material’s original shape. TPE can also be recycled repeatedly.

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There are two main types of polystyrene: general-purpose polystyrene (GPPS) and high-impact polystyrene (HIPS). GPPS is brittle and has less dimensional stability than HIPS, which is compounded with butadiene rubber to enhance its material properties. GPPS also has a glass-like clarity whereas HIPS is opaque.

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Two-Shot Injection Molding: Utilizes two different materials, often with different properties, colors, or textures. Common combinations include thermoplastics with different hardness or colors.

Two-Shot Injection Molding: Commonly used for creating complex parts with multiple colors, textures, or material properties in industries such as automotive (multi-color buttons, soft-touch grips), consumer electronics (multi-material casings), and medical devices (multi-material components with different tactile properties).

Overmolding: Utilizes standard injection molds for the substrate component, with additional features to accommodate the overmolding process. Mold design is typically simpler for overmolding vs two-shot injection molding, as it involves molding one material over another without the need for multiple injection cycles.

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Applications for acrylic injection molding include windows, greenhouses, solar panels, bathroom enclosures, and other transparent components for architectural, lighting, and outdoor applications.

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Compared to liquid silicone rubber (LSR), TPE is easier and less expensive to mold. Under sustained pressures, however, TPE is susceptible to creep, the tendency of a solid material to permanently deform. TPE also tends to lose its rubbery properties at higher temperatures and is significantly more expensive than other plastic injection molding materials.

Acrylic is a strong, clear thermoplastic that provides a lightweight, shatter-resistant alternative to glass. This injection-molded material also offers excellent optical clarity so that a high percentage of light passes through. Acrylic resists ultraviolet (UV) light and weather, and is also known as PMMA, or by its full chemical name: poly(methyl methacrylate).

Two-Shot Injection Molding: Requires specialized molds with multiple cavities or rotating cores to facilitate the injection of two materials in separate shots. Mold design complexity is higher, and the process may require additional mechanisms for material transition and registration.

Applications for TPU injection molding include footwear, gaskets, caster wheels, and sporting goods along with cases or enclosures for electronics and medical devices. In medical applications, TPUs are sometimes used instead of polyvinyl chloride (PVC), a plastic that may cause skin irritation.

In its pure form, acetals have low impact strength and a very high rate of thermal expansion. Yet, POM can be reinforced with fiberglass or minerals for improved strength and stiffness. Compounds that are reinforced with both provide an excellent balance of mechanical properties. Because injected molded POM lacks resistance to sunlight, its outdoor applications are limited.

Unlike some plastics, acrylic can withstand exposure to water and hold tight tolerances. PMMA won’t absorb odors, but it cannot resist solvents and is easily stained by greases and oils. Although injection-molded acrylic has high tensile strength, it’s prone to stress cracking under heavy loads.

With its low coefficient of friction, injection-molded POM is used in bearings, gears, conveyor belts, and pulley wheels. Additional applications include fasteners, eyeglass frames, parts for knives and firearms, lock systems, and high-performance engineering components.

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PE plastics come in numbered grades where higher numbers generally indicate higher densities. For example, HDPE 500 has a higher density than HDPE 300. Both grades have a higher density than LDPE, which also uses a numbering system for grades. BASF and DuPont are two of the leading suppliers of PE for engineering (as opposed to general-purpose) applications.

There are two main types of acetal plastics: homopolymers, which provide higher hardness and tensile strength, and POM copolymers. Neither type of material can be fire-rated to a standard such as UL 94, and both experience relatively high shrinkage during injection molding. Popular brand names for POM plastics include DuPont Delrin® and Ensinger TECAFORM®.

ABS is known for its strength and impact resistance, but it lacks strong resistance to sunlight (UV), water, and weather. Compared to acrylic, injection-molded ABS is not a good choice for outdoor applications. ABS also generates significant smoke when burned and, unlike nylon, provides poor resistance to high friction.

Overmolding: Involves molding one material over another substrate (typically a rigid plastic or metal component) to create a single integrated part with multiple layers.

Plastic materials for injection molding range from commonly used polymers to specialty plastics and polymer blends. There are hundreds of different plastic resins available, and they each have different end-use properties and processing requirements. Plus, there are different grades of the same plastic material, including resin types with fillers such as glass fibers or carbon fibers, and specific brand names.

Nylon is a synthetic polyamide (PA) that combines toughness and high heat resistance with high abrasion resistance, good fatigue resistance, and noise-dampening properties. Nylon isn’t inherently flame-resistant, but flame-retardant versions are available. Similarly, although nylon can be degraded by sunlight, a UV stabilizer can be added to improve outdoor performance.

Polypropylene is the second most commonly used plastic in the world. It provides good chemical resistance, retains its shape after torsion or bending, has a high melting point, and won’t degrade when exposed to moisture or water. Injected molded polypro, as PP is sometimes called, is also recyclable.

If you’re looking to enhance your product with overmolding or two-shot injection molding, we’re here to support you through every step of the process, from design optimization and material selection to secondary processes and quality assurance.

When it comes to comparing the advantages of overmolding vs two-shot injection molding, it’s important to mention which method is best suited for certain parts.

Polyoxymethylene (POM) is an engineering plastic that is also known as acetal. It combines excellent rigidity with thermal stability and has a low coefficient of friction. This plastic material has low water absorption and good chemical resistance. In terms of appearance, POM plastics are naturally opaque and white in color.

Automotive applications include weather seals and shock dust boots. Medical applications include breathing tubes, valves, catheters, and ventilation masks.

Pure polypropylene is a commodity plastic with the lowest density, but high crystalline polypropylene (HcPP) is filled with glass fibers for rigidity. Semitron® from Mitsubishi Chemical Advanced Materials is a leading brand.

Polyethylene is the most commonly used plastic in the world and is a commercial polymer that can be selected according to its density. High-density polyethylene (HDPE) and low-density polyethylene (LDPE) both provide chemical resistance, but they differ in terms of their hardness, flexibility, melting point, and optical transparency.

Overmolding: Typically involves using two different materials as well, with one acting as the substrate and the other as the overmold material. The substrate is usually rigid, while the overmold material is flexible.

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Founded in 1950, Thogus is an established, family-owned custom plastic injection molder and contract manufacturer headquartered in Avon Lake, Ohio.

The plastics discussed in this article are the most common injection molding materials — including specialty plastics and polymer blends — that Fictiv can injection mold for you.

With so many options, it helps to have an expert’s advice before choosing a plastic resin for your project. As part of our injection molding service, Fictiv has design and production experts ready to help you make the right choice, and you get design for manufacturing (DFM) feedback along with your quote.

In contrast, overmolding is the method to go with if your primary goal is enhancing functionality or visual appeal, or to improve specific features of a part. Examples include:

Injection-molded polycarbonate is sometimes used instead of acrylic because PC maintains its physical properties over a wider temperature range. PC requires high processing temperatures, however, which can make it more expensive to mold. With its predictable and uniform shrinkage, however, polycarbonate offers precise dimensional control for tighter tolerances.

Polystyrene can be filled with glass for added strength or co-polymerized with acrylic for greater clarity and improved chemical and UV stability. Brand names include American Styrenics PolyRenew® and BASF Polystyrol®.

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Common brand names for acrylic plastics include Trinseo PLEXIGLAS®, which is available with high heat resistance, and DuPont LUCITE®, which has excellent optical clarity and transparency.

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In general, two-shot injection molding is best for creating complex parts with contrasting colors, textures, and material properties. Some common parts made with two-shot molding include:

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Compared to TPE, TPU has superior resistance to extreme temperatures and chemicals. TPUs may be too hard for some injection molded plastic parts, and tend to cost more, in part because drying is required before processing.

Overmolding: The pros of overmolding include enhanced product functionality and aesthetics, improved ergonomics and grip, and added value to the product. Overmolding also allows for the combination of different materials with complementary properties. As for the cons, overmolding is often limited to applications where a rigid substrate is suitable for overmolding. It may require secondary operations for part preparation or substrate treatment.

Thermoplastic polyurethanes come in commercial, medical, and industrial grades. There are three main classes of TPU materials: polyester, polyether, and polycaprolactone. Trademarked products are available from manufacturers such as Lanxess, Lubrizol, Texin, and Ultralast.

Two-Shot Injection Molding: Also known as dual-shot, multi-shot, or 2K molding, it involves injecting two different materials into a single mold in two separate cycles to create a single integrated part.

Polystyrene plastics are lightweight, relatively inexpensive, and resistant to moisture and bacterial growth. These commodity plastics also provide good chemical resistance to diluted acids and bases and have excellent resistance to gamma radiation, which is used to sterilize medical devices.

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ISO 18064 defines generic classes of commercial TPEs. There are many different manufacturers and brand names, including Teknor Apex Telcar®, Kraiburg HIPEX®, and Dynaflex™ from Avient (formerly PolyOne). Healthcare-grade TPEs are available.

TPU is a type of TPE that is often called out separately because of its popularity. It has a rubber-like elasticity, and can be used as a replacement for hard rubber because of its higher durometer. Injection-molded TPU also has good load-bearing capabilities and can withstand exposure to ozone.

Overmolding: Similar to two-shot molding, overmolding requires compatible materials for proper adhesion. The substrate material must also be capable of withstanding the temperatures and pressures of the overmolding process without deforming or degrading.

Two-Shot Injection Molding: Pros include the production of complex parts with reduced assembly steps, and improved part quality. Two-shot molding also offers design flexibility and aesthetic options. The cons include a higher initial investment in tooling and equipment, limited material options, and potential challenges with material compatibility and adhesion.

This article discusses their properties, including comparisons to other materials, along with injection molding applications, grades, and brand names for each.

Polycarbonate plastic can be filled with glass and is available in grades that contain a relatively small percentage of stainless steel fiber. Popular brands include SABIC Lexan®, which is available in flame-resistant versions, and Covestro Makrolon®, which has glass-like transparency.

When it comes to plastic injection molded components, there are nearly as many needs as there are applications. As a result, one size does not fit all when it comes to the manufacturing processes chosen to produce plastic parts. While injection molding is one of the most efficient and versatile manufacturing processes available, there are different methods within injection molding that offer an even higher level of customization and adaptability. Two of the most widely used methods are overmolding and two-shot injection molding. Both differ in their applications and approaches. Let’s take a look at the contrasts between overmolding vs two-shot injection molding, and when one might be preferred over the other.

Compared to other plastics, nylon provides poor resistance to strong acids and bases. Nylon is not as strong as polypropylene and can’t match polycarbonate for impact resistance. Injection molding nylon is challenging because it’s prone to shrinkage and is subject to inadequate mold filling.

At Thogus, we specialize in mid- to high-volume injection molding services for a wide range of industries and applications. We have decades of experience and extensive capabilities that include traditional injection molding, overmolding, and two-shot molding, as well as gas-assisted injection molding. As a result, we can customize our manufacturing services to meet the specific needs of your project with a focus on white glove customer service.

PE plastics include polyethylene terephthalate (PET, PETE), a material that is not defined by its density. Like LDPE, PET can be as clear as glass; however, designers can also select grades of PET or PETE with different levels of optical clarity. HDPE, LDPE, and PET all resist moisture and chemicals, but LDPE is softer and more flexible than HDPE, which is an opaque material.

Despite its comparative advantages, polypropylene degrades with UV light and is extremely flammable. At temperatures above 100° C  (212° F), this injection-molded plastic dissolves into aromatic hydrocarbons, such as benzene and toluene, which are harmful to humans. Polypropylene plastic is also difficult to bond and paint.

Polycarbonate is strong, lightweight, and naturally transparent. This plastic injection molding material has excellent optical properties to support light transmission, but maintains its color and retains its strength when pigmented. Although it isn’t scratch-resistant, polycarbonate is significantly stronger than glass and is extremely durable.

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With so many choices, it’s daunting to choose the right material for your project. Whether your project involves medical plastic injection molding, molded plastic components for the automotive industry, or something else, Fictiv experts are ready to help you go from design to production quickly.

Applications for polystyrene injection molding include medical, optical, electrical, and electronic applications. With its higher impact strength, HIPS is often used with appliances and equipment, while injection-molded GPPS is used in plastic toys, cases, containers, and trays.

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Overmolding: Often used for adding functional or aesthetic features to existing parts, improving grip, providing cushioning, or sealing against moisture or contaminants. Common applications include tool handles, toothbrushes, electronic device casings, and medical device grips.

Applications for polyethylene injection molding may be limited to indoor applications because of their poor UV resistance. Because they are unable to withstand high service temperatures, these plastic materials may not be suitable for some processing applications. Often, injection molded polyethylene is used in products such as housewares, toys, food containers, and automotive parts.