Everything You Need to Know About Injection Molding

Whether you want to take an idea from concept to prototype or move a design into full production, injection molding is a suitable manufacturing solution. Below, we provide an overview of injection molding, outlining what it is, how the process works, and what to consider when planning an injection molding project.    

What Is Injection Molding?

Injection molding is a manufacturing process that involves the injection of molten materials into preformed molds. It is used to create parts and products in a wide range of shapes and sizes in low and high volumes.

There are many injection molding variations, each of which requires the heating and melting of material, injection of the molten material into a mold, and cooling of the material within the mold to form the desired component. Three of the main methods utilized differ based on the material used:

•   Plastic injection molding uses thermoplastic resin pellets. It is suitable for prototyping and production.
•   Liquid silicone rubber (LSR) injection molding uses thermoset rubber. It is suitable for prototyping and small-run production runs.
•   Die casting uses metal (e.g., aluminum, copper, magnesium, or zinc). It is suitable for high-volume production runs.

How Does the Injection Molding Process Work?

While the injection molding process may vary from project to project, depending on the part and production specifications, it typically consists of the following steps:

The Mold is Designed & Created

While there are standard molds available for injection molding operations, many projects require custom molds. These customized components must be designed and built to suit the desired product. Once the molds have been sourced or created, the injection molding process can begin.

The Mold is Installed in the Injection Molding Machine

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The mold must be properly positioned and affixed within the injection molding machine to ensure high product and process quality.

The Material is Fed into a Heated Barrel

The injection molding material form depends on the material. For example, plastic typically comes in pellet form. Regardless of type or form, the material is heated until it reaches its liquid state.

The Molten Material is Injected into the Mold

Once the material is fully melted, it is injected into the mold, which is securely closed to ensure the material does not leak out.

The Material is Cooled Until it Resolidifies

The molten material cools as soon as it comes into contact with the mold. It is allowed to continue to cool until it has solidified, which enables it to maintain the shape of the mold even after it has been ejected.

The Molded Component is Ejected From the Mold

Once the material has fully cooled, the component is ejected. Afterward, it can be packaged for shipment or further processed as needed.

What Should I Consider When Planning an Injection Molding Project?

There are many factors to consider when planning an injection molding project. Some of the questions you should answer before beginning the project include:

•   What is the design of the part? Is it simple or complex? Do you have it finished, or do you still need to create one?
•   What is the construction material for the part? Is it inexpensive or expensive? Is it readily available or hard-to-find? It is easy or difficult to work with?
•   How many pieces of each part do you need? Do you require prototype or production volumes? Is this a short-run or long-run operation?
•   Are there exact specifications and standards that must be met? Do the molded components need to accommodate any application or industry requirements and restrictions?
•   Do you have a specific delivery timeline? Do you need the parts within a certain time period? Is standard processing time fine, or is expedited processing required?
•   Do the molded parts require assembly? Will the parts needed to be assembled after they are molded?

If you’re outsourcing your prototyping and/or production operations, the injection molding company you partner with should be able to meet all of your requirements and restrictions.

Injection Molding Services at Advanced Prototype Molding

Looking for an injection molding company that is as committed to your project success as you are? Advanced Prototype Molding is the ideal partner!

At Advanced Prototype Molding, we are a full-service injection molding company. We provide design, mold engineering, injection molding, assembly, finishing, and many other related services all under one roof, which enables us to turn our customers’ concepts into reality while saving them time and money.

To learn more about our injection molding capabilities, check out our injection molding services page or contact us today. To partner with us on your next injection molding project, request a quote.