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Custom Injection Molding Service
Custom injection molded plastic parts are common in many types of applications, with a global market value estimated at nearly $360.6 billion. Manufacturers across a range of industries continue to innovate around proven and emerging benefits of plastics, seeking answers to complicated challenges and customer demands, and partnerships with injection molders that can produce unique solutions.
The worldwide availability of molding methods may suggest that any choice is a good one, but strategic manufacturers understand that the types of molding and services offered vary greatly.
Custom plastic injection molding for sophisticated, high-quality applications in specialized markets demands multiple scientific methods, analytical tools, and advanced molding process technologies – and not all molders have what it takes. Meeting precision and performance standards requires injection molder expertise and focus on four key stages of product development:
- Part design
- Materials selection
- Tool design
- Process control — scientific molding, insert molding, overmolding, etc.
Partnering with the appropriate injection molder and leveraging key processes gives manufacturers a competitive advantage in the near and long term.
Not every injection molder is qualified to engineer sophisticated injection molded plastic parts and components. The same can be said for other molding methods which, in comparison to custom injection molding, are limited:
- Blow Molding
- Compression Molding
- Extrusion Molding
- Rotational Molding
- 3D Printing
For manufacturers with project-specific needs, complex geometries, or any other detailed challenges, custom plastic injection molding provides numerous advantages:
- Precision
- Strength
- Part/Product Consistency
- Simultaneous Use of Multiple Plastics
- Lightweighting
- Multiple Finishes
- Color Control
- Shorter Product Development Timeline
Partnering with a custom injection molder, like Kaysun, with the experience and insights to drive improvements in complex applications – from the product design phase through production – allows opportunities for process optimization through:
Design for Manufacturability (DfM): The process of consciously and proactively designing parts to optimize all facets of manufacturing, including injection molding.
Scientific Molding: A combination of material science and precise measurement specialized engineers use to completely discern – down to the molecular level – what’s happening during every stage of the injection molding process. Fully understanding how all the different parameters interact in detail helps ensure that high precision is maintained across multiple production runs. Because all the data is recorded, it is easy to replicate the manufacturing process as needed, even when production is transferred from one machine to another, saving a tremendous amount of setup time.
Moldfill Analysis: A sophisticated computer program that analyzes and predicts the flow and cooling of plastic during all phases of the injection molding process. Levels of mold filling analysis vary from simulating fill and packing phases to optimize gate location, gate sizes, and process conditions, through more advanced simulations comparing runner systems, mold temperatures, and fiber orientation to gauge shrink and warp.