Thermoforming involves heating a plastic sheet until it becomes pliable and then forming it over a mold to create the desired shape. The sheet is then trimmed to create the final part.

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Customer cases have demonstrated that the switch from fossil-based plastics to PLA for injection molding is very much possible, all without major financial investments.

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While injection molding remains a cornerstone of mass production for high-quality plastic parts, its high costs can be a barrier for many applications. Alternatives such as 3D printing, CNC machining, vacuum casting, resin casting, thermoforming, and blow molding offer more cost-effective solutions for varying production needs. Each method comes with its own set of advantages and limitations, making them suitable for different types of projects, volumes, and material requirements.

Resin casting involves creating molds and then filling them with liquid resin to produce parts. This method is widely used for producing small parts, models, and prototypes.

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Blow molding is a process used to create hollow plastic parts, such as bottles and containers. It involves inflating a heated plastic parison (a tube-like piece of plastic) inside a mold to form the desired shape.

A Release Agent facilitates the separation of the cured part from the mold. SUKANO® Mold Release Masterbatch migrates to the surface of the final product facilitating demolding of the injection molded part from the metal surface of the cavity, hence reducing the demolding force.

Injection molding is a popular manufacturing process known for producing high-quality, precise, and consistent parts in large quantities. However, its high initial tooling costs and setup expenses can be prohibitive for small-scale productions or startups with limited budgets. Fortunately, several alternative manufacturing methods can be more cost-effective, especially for lower volumes or less complex parts. This article explores these cheaper alternatives to injection molding, highlighting their advantages, limitations, and suitable applications.

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Vacuum casting, also known as silicone molding, is a process where a master model (often created using 3D printing or CNC machining) is used to make a silicone mold. This mold is then used to cast parts in various materials, typically polyurethane resins.

3D printing, or additive manufacturing, is one of the most accessible and cost-effective alternatives to injection molding for low to medium-volume production. It involves creating parts layer by layer from digital models, using various materials such as plastics, metals, and resins.

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By understanding these alternatives, manufacturers can select the most appropriate and economical method for their specific needs, ensuring efficient and cost-effective production without compromising on quality or performance.

CNC (Computer Numerical Control) machining is a subtractive manufacturing process where the material is removed from a solid block (workpiece) to create the desired shape. It is highly precise and suitable for both plastic and metal parts.

A bigger shift toward PLA in injection molding has been slowed by serious processing issues. There are several challenges that convertors have faced when processing injection molded PLA parts, especially when using existing equipment and tools, including:

SUKANO ® Mold Release Masterbatches can reduce the friction between the polymer chains. This leads to a lower melt viscosity and therefore a higher melt flow without increasing the temperature. This can help to fill the cavities, especially in thin wall applications.