As the mold size increases, the Price Factor decreases. Small molds have lower material costs, yet the reduction in other expenses is not as significant. Conversely, with larger molds, the increase in other costs does not scale proportionally with the rise in material costs.

Optimal drying of PLA pellets: To ensure that the PLA pellets are free of moisture and ready for processing, it is important to dry the pellets to a specified moisture content using a dehumidifier or dryer. The drying temperature and time will depend on the type of PLA used and the moisture content.

Cooling and demolding: The mold is cooled using a combination of water and air circulation to ensure that the part solidifies quickly and evenly. The cooling time will depend on the size and shape of the part, as well as the mold design. Once the part has solidified, the mold is opened, and the part is removed from the mold.

Low melting point and thermal stability: The low melting point and thermal stability of PLA can make it difficult to achieve consistent results, especially when producing parts with complex shapes and tight tolerances. To overcome this challenge, it is important to use a high-quality, virgin PLA material and to adjust the processing conditions accordingly.

Warping and shrinkage: One of the most significant challenges in PLA plastic injection moulding is warping and shrinkage. This is due to the lower melting temperature and higher thermal stability of PLA compared to conventional petroleum-based plastics. To minimize warping and shrinkage, it is important to use a proper mold design, with adequate gating and runner systems, and to control the mold temperature and cooling rate.

Where P20 – low end; 718H (medium); H13 (high end), these mold steels are the most commonly used.C45 is also sometimes used in low-end applications.

Before you make the final decision to place the order, it makes sense to ask 2 or 3 suppliers to submit you the cost break down for the mold, so you will know whether the costs have been calculated correctly, and which supplier appears to be more professional in the quote process.

Simple geometric molds can be efficiently machined using larger milling tools, requiring less time. In contrast, molds with complex shapes necessitate the use of smaller milling tools for detailed work, and some parts may require EDM (Electrical Discharge Machining), significantly extending the machining time.

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It makes sense to know what are the most common percentage of each cost, so you will know if the quotes you receive are calculated properly, and if the prices are competitive:

Injection molding machine and components: The injection molding machine consists of several components, including the hopper, barrel, screw, nozzle, and mold. The hopper is where the PLA pellets are stored, while the barrel is where the heating and melting of the material take place. The screw is responsible for conveying the melted material to the nozzle, and the nozzle is responsible for injecting the melted material into the mold.

Material costs generally constitute 20-35% of the total mold price. However, for some larger and simpler molds, the material costs can represent 60-70% of the total cost, such as the chair shown in the example below.

Small mold manufacturers may devote more attention to each project, but their capabilities vary widely. Some may lack the necessary skills to achieve quality results, so discernment is crucial.

A mold consists of many parts, each requiring various machining processes, making its cost calculation complex. While determining the cost of materials can be relatively straightforward and precise, calculating processing costs is more challenging.

Although the complexity of injection molds may differ, with some displaying elaborate designs and multiple moving parts, their fundamental structure remains unchanged.

Porosity and sink marks: Porosity and sink marks are common defects that occur when the material does not fill the mold cavity evenly, resulting in air pockets and surface imperfections. To minimize porosity and sink marks, it is important to use a high-quality, virgin PLA material and to adjust the injection speed and pressure accordingly.

Selection of appropriate process conditions: To achieve the best results, it is important to select the appropriate process conditions, including the injection speed, pressure, and cycle time. These conditions should be adjusted based on the size and shape of the part, as well as the material properties of the PLA.

A skillful designer’s hourly rate can be 30 to 40 dollars, this sounds a bit high, but they can finish the design of 8-10 simple injection molds in a day (12 hours), so their charge is reasonable for their output.

However, for some plastic parts with special requirements, the price calculated by this calculator will be low, such as this LED lamp lens, which will give a much lower price than the actual price. This is because the lens has high requirements for the projected light pattern, and its geometric shape accuracy is very high.

As mentioned above, some costs, especially machining and assembly fees, cannot be precisely estimated when calculating quotations. Only the fuzzy quotation method can be used. The so-called fuzzy quotation is that it will be the quotation actually slightly upward than the actual cost, but there is also the possibility of downward fluctuation. And the upward and downward fluctuations between different costs may offset each other, to achieve the overall fluctuation is not very large.

Here are some examples of mold prices to verify the accuracy of the mold price calculator. It can be seen that for plastic products with general complexity and accuracy, its valuation is still close.

The hardness of standard mold steel ranges from HRC28 to HRC54. Mold steels with higher hardness require heat treatment followed by precision machining, making the harder molds more expensive due to the longer processing time.

Yes, PLA (Polylactic Acid) can be injection molded. PLA is a thermoplastic material that can be melted and molded into various shapes and sizes using the injection molding process. This process involves heating the PLA pellets to a molten state and injecting them into a mold under high pressure. The mold is then cooled, and the solidified part is removed from the mold. PLA is a popular material for injection molding due to its eco-friendliness, biodegradability, and lower melting temperature compared to conventional petroleum-based plastics. However, there are some challenges associated with injection moulding PLA, such as warping and shrinkage, porosity and sink marks, and degradation and degradation products, which need to be overcome to achieve high-quality and consistent results.

Use of high-quality, virgin PLA material: To achieve the best results and minimize defects, it is important to use high-quality, virgin PLA material. This will help to reduce porosity and sink marks, as well as minimize degradation and degradation products.

The mold is then cooled, and the solidified part is removed from the mold. The cooling time will depend on the size and shape of the part, as well as the material properties of the PLA.

Tall ribs/posts are equivalent to deep grooves/holes within the mold, requiring the application of Electrical Discharge Machining (EDM). Additionally, this will present challenges during the injection molding process and elevate the manufacturing cost of the components.

This is due to the fact that pricing is based on the mold’s net weight, yet the actual material used often exceeds this amount. Furthermore, the pricing doesn’t account for mold accessories, which are sold as complete products not priced by weight, nor does it include the materials for electrical discharge machining (EDM), such as copper or graphite electrodes. These factors add complexity to the mold’s pricing structure.

In contrast, the hardness of pre-hardened tools typically ranges from HRC28 – 40. These are made from steel that has undergone a pre-hardening process, eliminating the need for heat treatment and allowing for direct machining to the final dimensions.

Machining is the most expensive part of the mold. The cost also depends on the type and grade of the machining equipment. The hourly rate of top brand equipment is 2-3 times higher than that of ordinary equipment.

For instance, the type of injection mold depicted in the right-hand image, used for manufacturing dispenser caps, typically costs between $12,000 and $18,000.

Since it is hard to estimate the machining time accurately, we can only make an approximation based on the size of the plastic part and the actual processing cost of similar parts in the past.

This online injection mold cost calculator uses the part dimensions, the number of cavities, and the number of slides to calculate the mold dimensions and then estimate the mold price. It is not 100% accurate but can provide a close enough estimation.

Make sure the length (L) is bigger than the width (W), otherwise, their values will switch automatically.Note: Maximum value for L, W and H: 600mm          Minimum value for L, W and H: 8mm (please use 8mm if the value is smaller)

Pre-processing of PLA pellets: Before the injection molding process can begin, the PLA pellets need to be pre-processed. This includes drying the pellets to a specified moisture content to prevent degradation and improve processing conditions. The drying temperature and time will vary depending on the type of PLA used and the moisture content.

Certain features require EDM (Electrical Discharge Machining) to be completed, utilizing electrodes made from copper or graphite.

The mold assembly is time-consuming work. It includes adjusting the dimensions that are not in place during machining, making all the moving parts fit with appropriate tightness, and debugging the issues that were not anticipated in the design stage. The more complex or the more expensive the mold is, the longer it takes to match the mold. For example, a 10,000-dollar worth of mold may take 50-100 hours to match.

The complexity levels are divided into five categories: very simple, simple, medium, complex, and very complex. A “simple” classification indicates minimal small details, lower precision requirements, fewer and smaller sliders, and lower ribs. On the other hand, a “complex” classification suggests the presence of more intricate details, higher precision, larger and more sliders, and taller ribs, essentially the reverse of the simple category.

Injection molding is a widely used manufacturing process for producing parts by injecting molten material into a mold. The mold is then cooled, and the solidified part is removed from the mold. Injection molding is fast, efficient, and cost-effective for producing high-volume parts with tight tolerances and complex shapes.

Injection molding process: The injection molding process begins with the melting of the PLA pellets in the barrel. The melted material is then conveyed to the nozzle and injected into the mold. The mold is clamped under pressure, and the melted material fills the cavities of the mold.

Likewise, we will do the same calculation for the other steel plates and sliding components to get their weight and costs, and add them together.

The cost calculation of the injection mold starts from the material cost. First, we will calculate the costs of the main steel plates.

Controlled mold temperature and cooling rate: To minimize warping and shrinkage and to achieve a consistent part quality, it is important to control the mold temperature and cooling rate. The mold temperature should be maintained at a consistent level, and the cooling rate should be adjusted accordingly to ensure that the part solidifies quickly and evenly.

By following best practices and considering the factors discussed above, it is possible to achieve high-quality and consistent results in PLA plastic injection moulding.

Due to the common occurrence of undercuts in the designs of plastic parts, injection molds frequently include sliding mechanisms. These mechanisms are primarily of two types: one that transforms vertical movements into horizontal ones using inclined rails, and another that employs hydraulic or pneumatic cylinders for movement.

The rationality of the design, such as the design of the gate and the arrangement of cooling channels; the precision of the machining, with minimal marks from later refinements; and a manual test of pushing the ejector plate, which should move smoothly, indicating overall machining accuracy.

A successful plastic molding project starts from a good mold design, which requires a lot of skill and experience and often involves teamwork. Designers, mold makers, and others collaborate and combine their input to find the best option.

Depending on the size and complexity of the mold, the design fee usually ranges from $100 to $300, sometimes could be even higher.

Molds featuring a higher number of cavities often employ hot runners to ensure even pressure and flow distribution at each gate. Such molds demand greater dimensional uniformity across cavities, posing higher risks for the mold maker. These elements contribute to an increase in pricing.

Post-processing and finishing: The final step in the injection molding process is post-processing and finishing. This may include trimming the gate, removing any flash, and sanding or polishing the surface of the part. The final step is to inspect the part for defects and ensure that it meets the desired specifications.

The top ejector plate has many holes for installing and positioning the ejector pins, whereas the bottom ejector plate lacks holes and serves to push the ejector pins.

♦ Product material: PP♦ Product dimension: 150*150*15mm♦ Mold material: 718H♦ Number of cavities: 1♦ Ejection method: ejection plate

Now, to help you better understand how the mold cost is calculated, let’s take a look at an example in the table below. Please note that we have given the hourly rate of different processes, so that you can understand how each cost is calculated.

This calculator will give 2-3 prices, each corresponding to a different complexity level, so that you can get a price range that provides a better reference. Each price provides a cost breakdown and their percentage.

The process of PLA injection moulding consists of several stages, from pre-processing the raw material to post-processing the finished part. The following is a step-by-step guide to the process of PLA plastic injection molding.

When calculating the raw material dimensions, some allowance needs to be added to the length, width, and height. Then we have the material weight of the Cavity Plate.

As the ejector plates move upwards, they drive the ejector pins, which then eject the cooled plastic part from the mold.

There are many types and grades of hot runners, with prices ranging from a few hundred to several thousand dollars, and they require the use of a temperature control unit. While hot runners offer significant benefits, they also lead to an increase in costs.

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As a result, it is more susceptible to degradation during processing and storage. Additionally, PLA is more hygroscopic, meaning that it absorbs moisture from the air, which can affect its mechanical properties and processing conditions.

These are the results obtained from the simulation calculator. If you would like a more accurate and realistic manual quote, please contact us

Proper gate and runner design: To ensure that the melted material fills the mold cavity evenly and without any defects, it is important to use a proper gate and runner design. The gate and runner design should be optimized for the size and shape of the part, as well as the material properties of the PLA.

In recent years, there has been a growing demand for eco-friendly and sustainable products. As a result, more and more manufacturers are turning to bio-based plastics, such as Polylactic Acid (PLA), as a substitute for conventional petroleum-based plastics. PLA is a biodegradable and compostable material made from renewable resources, such as corn starch, sugarcane, or cassava. When it comes to producing complex and high-volume parts, injection molding is the ideal process to consider. In this blog post, we will dive into the world of PLA injection molding, and explore the benefits, challenges, and best practices of this fascinating process.

While PLA plastic injection moulding offers many benefits, there are also several challenges that need to be overcome to achieve high-quality and consistent results. Some of the most common challenges include:

When the product size is L*W, and there are 2 cavities, then the distance between cavities R, and the distance from cavities to edges T1, T2 can be obtained from empirical formulas, so we can get the length and the width of the cavity plate Lca and Wca,

There are 3 options here: no slider, 1 side of sliders and 2 sides of sliders  Note: If there are multiple sliders on the same side, they are considered 1 side of sliders.

The majority of mold prices fall between $1,000 and $10,000. However, the cost of some large-scale molds, such as those used for automotive parts, can reach several hundred thousand dollars.

The cost of molds based on weight typically ranges from $8 to $50 per kilogram. This variation is influenced by the type of steel used for the mold, as well as the mold’s complexity and size.

This is because achieving higher accuracy necessitates the use of more sophisticated and expensive equipment, as well as slowing down the tool’s movement (feeding) to reach the desired level of precision.

Our online mold cost calculator will help you determine an appropriate price for your mold and explore ways to potentially reduce the mold investment.

Setting the machine parameters: The machine parameters, such as the injection speed, pressure, and temperature, must be set correctly to ensure that the finished part meets the desired specifications. The injection speed and pressure determine the flow rate and packing pressure of the melted material, while the temperature determines the viscosity and flowability of the material.

Tax and profit: Except for the tax and other overhead fees, a reasonable profit margin should be around 15-30%. Sometimes it may be a little higher for more challenging jobs, the extra profit is for the risk (uncertainty) the mold maker is going to take. Remember the mold manufacturer is responsible for delivering the final result, which is the injection mold that can smoothly produce the plastic parts with good quality, but not merely making a mold that ends up with excessive molding defects.

The ejecting mechanism consists of ejector pins and the top and bottom ejector plates, playing a crucial role in seamlessly releasing the formed parts from the mold.

To achieve high-quality and consistent results in PLA injection molding, it is important to follow best practices and to consider the following factors:

In the above quotation methods, each cost is estimated separately. But in actual operation, mold factories often use simpler methods, that is to calculate material costs first and multiply by a price factor according to the mold size, complexity of the mold and so forth.

An injection mold consists of several precision-engineered steel parts. These parts are meticulously shaped and honed to specific dimensions and tolerances, then assembled to form a complete mold. This assembly serves as the vessel for injecting, shaping, cooling, and solidifying of molten plastic to form the finished part.

PLA is a thermoplastic polymer that has several advantages over conventional petroleum-based plastics. First and foremost, it is a bio-based material, making it a more sustainable option for consumers and manufacturers alike.

Based on the size of the plastic parts, the number of cavities, and the basic structure (whether there are sliders, cores, two-plate molds or three-plate molds, etc.), we can calculate the size and weight of the steel plates and then get the cost of them.

To provide a quotation for a mold, it’s necessary to first design the mold structure. Following that, you calculate the cost of materials, estimate machining and additional costs, and then finalize a quote for the mold.

Large mold manufacturers possess strong technical capabilities, yet they may not prioritize your project as highly. Although the risk is lowest with large manufacturers, collaboration with them might lack flexibility and adaptability.

All in one service for new product development from part design, PCB design, prototyping, testing, mold/die/tooling making, massive production, assembly, inspection, and packing.

Processing costs depend on the type of equipment used and the time it takes to complete the process. Accurately predicting processing time is difficult, whether through human estimation or using 3D simulation software. As a result, mold pricing often relies on estimates.

Regular maintenance and cleaning of the mold: Regular maintenance and cleaning of the mold will help to ensure that the mold is in good condition and that the parts are produced consistently. This includes cleaning the mold after each cycle, checking for any wear or damage, and repairing or replacing any worn or damaged parts as necessary.

If you’re considering outsourcing a plastic injection molding project, you might be curious about how to secure a reasonable price for the injection mold. In this article, we’ll break down the cost calculation for an injection mold. We’ll delve into the hourly rates associated with each manufacturing process, along with the key factors that influence the mold’s cost.

However, there are some characteristics of PLA that affect its suitability for injection molding. For instance, PLA has a lower melting temperature and a higher thermal stability compared to petroleum-based plastics.

Sometimes, electrodes can be made small, but at other times, they must be as large as the entire part. The material costs and machining expenses of these electrodes contribute to an increase in the mold’s cost.

Medium-sized manufacturers might offer less focus on your project and cannot guarantee their technical proficiency, similar to smaller factories.

In conclusion, PLA injection molding is a versatile and eco-friendly process that offers many benefits, including reduced emissions, lower energy consumption, and improved sustainability. However, there are also several challenges that need to be overcome to achieve high-quality and consistent results.

If a small mold manufacturer quotes a base price, a medium-sized manufacturer may quote 1.5 to 2 times that amount, while a large manufacturer might quote 2 to 2.5 times the base price. This variation is due to differences in overhead costs and profit expectations among the manufacturers.

Degradation and degradation products: Degradation and degradation products can occur when the PLA is exposed to high temperatures, moisture, and UV radiation. To prevent degradation and degradation products, it is important to store the PLA pellets in a dry and cool place, and to use proper drying and processing conditions.

Although the price of mold steel, which ranges from $2 to $20 per kilogram, might suggest that mold costs are relatively high, this isn’t necessarily the case. Material costs alone can make up 20% to 35% of the total mold price, and can even surpass 50%.

Tip: The hardness of through-hardened molds generally falls between HRC46 – 54. They are used exclusively for high-volume production or with high-temperature plastics such as PPS, PEEK, and PES.

Since the steel for the Core and Cavity are made of more expensive steel, they are often embedded into the A/B plates so they can be made smaller.The calculator will automatically compare the results of embedded and single-piece designs and choose the better option.

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Upon closing, the Core Plate, Cavity Plate, and Slider form a sealed compartment where the plastic material is molded and solidified. Once the mold opens, these parts disengage, allowing the release of the solidified plastic item.

In addition, it is biodegradable and compostable, reducing its impact on the environment. Furthermore, it is a safe and non-toxic material, making it ideal for food packaging and medical applications. Finally, PLA has a low melting point and a high crystallization rate, making it suitable for injection molding.