Injection Molding

Whitepaper
Learn the processes, requirements, and limitations of injection
molding, the go-to manufacturing process for large-volume
plastic part production.

-February / 2023
 Table of Contents
The Basics of Injection Molding 05
What Is Injection Molding? 06

Brief History of Plastic Injection Molding 07

Injection molding process 08

The Advantages and Disadvantages of

the Injection Molding Process 15

Injection Tooling and Molding 17

By Materials 18

By the Number of Cavities 21

Injection Mold Surface Finishes 23

How to Choose Injection Molding & Tooling 29

Plastic injection Molding Materials 34

Nylon (PA) 35

ABS 36

POM 37

Polycarbonate (PC) 38

PTFE (Teflon) 39

Injection Molding Whitepaper - 02

PMMA 39

PVC 40

PEEK 40

High-Density Polyethylene (HDPE) 41

Polyethylene (PE) 41

Polystyrene (PS) 42

Fiber and Additives 42

Injection Molding Design Guide 43

Wall Thickness 44

Tolerances 45

Part Geometry 45

Draft 46

Radii 46

Undercuts 47

Gates 48

Ejector Pins 50

Common Industrial Applications

of Injection Molding 51
Automotive Parts 52

Medical Industry 53

Injection Molding Whitepaper - 03

Electronics 53

Aerospace Industry 54

Retail 55

Household Items 56

FMCG Industry 57

Construction Industry 58

Major Factors Affecting the Cost

of Injection Molding 59
Material Cost 60

Mold Cost 60

Labor Cost 60

Part Complexity 61

Mold Size 61

Production Volume 62

RapidDirect: The One-Stop Solution for

Injection Molding Projects 63

Injection Molding Whitepaper - 04

The Basics of Injection Molding
What is injection molding and how it works? When did it start and how it became so
popular in the industry? Are there any special requirements for the process and what
are the main factors that affect the overall quality of the results?

The following section will take a brief look at the basics of injection molding and shed
some light on how the process works.

The Basics of Injection Molding - 05

What Is Injection Molding?
In the simplest terms, injection molding is a plastic production technique that uses
granular polymers and melts them to create identical plastic parts in the shortest
time. The process utilizes molds to give shape to the melted plastic which solidifies
under pressure to give a durable and reliable plastic product.

Injection molding can create hundreds to thousands of parts and is among the most
cost-effective methods to produce plastic parts. In fact, the higher the volume, the
more economical production would be. Resulting in significant savings without any
compromise on the quality and other technical parameters.

The Basics of Injection Molding - 06

Brief History of Plastic Injection
Molding
The theoretical foundation of plastic
injection molding started in the 19th
century when the first molding machine
was patented. The machine was
simplistic relative to modern standards
and could only process certain
materials and had safety issues due to
flammability and other factors. That’s
why the production of plastic parts was
limited to simplistic items like combs,
and buttons at a very low scale.

The situation remained the same until 1930 when most of the popular thermoplastics
integral to modern industry were developed. They included polyolefins, polystyrene,
and polyvinyl chloride (PVC), which continue to deliver excellence and have cemented
their position in various industrial applications.

This development, combined with the additional demand for a cheaper and viable
alternative to metals led to modern injection molding setups. The American inventor,
James Hendry played an integral part by building the first extrusion screw injection
machines. With time, those machines slowly transformed the plastic molding industry
into what it is today.

The picture shows how the machines themselves evolved over time. This comparison
depicts the injection molding machines by Negri Bossi, one of the most famous
manufacturers in the market. As the fundamental principles of the process evolved, all
the manufacturers updated their machines to ensure that they are in line with the
recent technological advancements.

Today, plastic products perform exceptionally well in a variety of high-performance

industries and have a long service life. Additionally, modern processes continue to
make plastics easier and more economical to recycle, making plastics safer for the
environment as well.

The Basics of Injection Molding - 07

Injection molding process

In the simplest terms, the injection molding process starts by heating any
thermoplastic to the point of liquidation and then using existing molds to achieve the
required shapes. The industry also considers the preparation of the mold as part of the
process. It all starts from that stage and the process then shifts toward the creation of
the plastic part. Let’s look at three types of injection molding processes.

The Basics of Injection Molding - 08

Type 1: Plastic Injection Molding Process
The plastic injection molding process has two basic stages: Stage 1 involves designing
and creating the mold, and Stage 2 involves six repetitive steps.

Stage 1: Manufacturing the Mold

Mold creation is the most fundamental part of the process. Engineers use CAD and
CNC machining to determine the mold’s specifications and design. These
specifications include its geometry, dimensions, and even the texture of the
component.

When it comes to the injection molding process, the cost of making the mold itself is
the most significant expenditure you’ll undertake. Even the price of a typical mold that
can bear production runs of 1,000 to 10,000 units would fall between $2000 to $5000.
The cost of molds for complex parts is even higher.

The Basics of Injection Molding - 09

Manufacturing the right mold requires a high level of expertise and skills. Engineers
must also run several simulations and tests to verify whether the design meets their
requirements. High-quality aluminum or steel materials are also required to ensure
that the molds are durable enough to survive several production cycles. Fortunately,
3D printing has allowed the cost of manufacturing molds to drop, especially for low-
run injection molding.

The Basics of Injection Molding - 10

Stage 2: Make Plastic Part with Injection Mold

Stage 1 is all about finalizing the mold’s design and manufacturing it. After that, the
rest of the steps involved in the injection molding process are easy. The following are
the six repetitive steps to produce injection molded parts:

Step 1: Clamping
The clamping phase is a simple step
that initiates the injection molding
process. A typical injection mold has
two clamshell-style pieces. Here,
manufacturers use a machine to
press the two metal plates of a mold
together.

Step 2: Injection
The injection phase starts once the
clamping process is over. But, before
the injection begins, the plastic
should be melted by heat until it is
completely liquid. Then, inject the
liquid into the mold. While the process
might seem simple on paper, it’s not
exactly a walk in the park. It’s
necessary to ensure that the
temperature stays constant without
any variation throughout the process.
Otherwise, the mold will not set
properly.

The Basics of Injection Molding - 11

Step 3: Dwelling Step 4: Cooling

Dwelling erases any air pockets that This step is straightforward.

may have formed within the mold Manufacturers leave the mold alone

during the injection. The phase uses and allow the liquid to cool down. After

pressure to ensure that the meted liquid the solidified plastic liquid takes the

fills every cavity in the mold. shape of a specific part, it’s time to

safely take out the product from the

mold.

Step 5: Mold Opening Step 6: Ejection

The next step involves removing the part

Here, engineers use an ejection bar to
from the mold. For this, manufacturers
push the product out of the cavity.
use a clamping motor to safely remove
Excess material is cut down through
the product without damaging it.
cutters, and the final product is

delivered to the customers for use after

final inspection.

The Basics of Injection Molding - 12

Type 2: Overmolding

Overmolding is a popular and unique process where two different materials combine

to create a single new product. A rigid and durable plastic typically acts as the

substrate or base material. Afterward, another softer material either completely or

partially covers the parts to create a protective layer. The process may sound

straightforward and uncomplicated, but it’s important to do it right by carefully

selecting the right combination of materials and maintaining control over the injection

molding process.

Overmolding has a lot of industrial applications and potential and the following 4

types of overmolding parts are common in the industry.

Plastic over plastic Plastic over metal

Rubber over plastic Rubber over metal

The Basics of Injection Molding - 13

Type 3: Insert Molding
The fundamental principle of insert molding and overmolding is the same. The only
difference is that the base material in this case is a metal insert while a plastic layer
encases it. In this process, the metal part is added to the mold before the infection
stage. The thermoplastic flows to the metal base and takes the shape of the mold to
cover the metal component.

The Basics of Injection Molding - 14

The Advantages and
Disadvantages of the Injection
Molding Process
While injection molding is an excellent choice for many plastic applications, it has pros
and cons that limit its application in some aspects. The following table gives a
detailed comparison between the advantages and disadvantages of injection
molding.

The Advantages and Disadvantages of the Injection Molding Process - 15

 Advantages Disadvantages

High Efficiency High Set-up Costs

Plastic injection molding is known for its While the injection molding process is known

efficiency and fast production. Its high for being economical, the initial costs of

production output makes the process cost- setting up the process are quite expensive.

efficient and ideal for mass-production.Low Injection molding requires designing and

Waste: The process focuses on repeatability. molding before production can take place.

Even the leftover plastic pieces can easily be Some of these costs include manpower,

recycled, and reused. These facts make supervision costs, and material acquisition.

injection molding a green manufacturing

process compared to its other alternatives.

Lower Labor Costs Lead Time

Naturally, labor costs are a significant factor Introducing a new product requires a

for any manufacturing process like significant investment as well as time. It can

machining, casting, etc. Injection molding, take months of planning, designing, and

however, works automatically and needs testing to have the finished molds at hand. Of

minimal input. Thereby reducing the overall course, once you have the mold at hand, the

costs process can be finished quickly. However, the

time spent on creating the final part can’t be

ignored.

Complex Part Suitable for Small Parts

The injection molding process allows Injection molding is ideal for manufacturing

manufacturers to create a uniform and small and precise parts. However, creating

complex parts. Through the process, highly large parts using the process is excessive.

precise and high-quality parts can be Even making the mold for a large piece is an

created. enormous bill that you’ll have to pay.

Moreover, other processes, such as Plastic

Fabrication, are far more suitable for
manufacturing large parts and components.

Flexibility
Not only does plastic injection molding offer

the ability to create complex parts, but the

process is applicable to different materials

and colors.

The Advantages and Disadvantages of the Injection Molding Process - 16

Injection Tooling and Molding
There are several options when it comes to selecting the right tooling for any injection
molding project. Based on the aforementioned parameters, any selected option needs
to have the right cost, preparation time, and other technical factors.

Below are the common injection molding tooling methods to ensure quality and
consistency in the design and products.

Injection Tooling And Molding - 17

By Materials

1 . Steel Molds

Durable, consistent, and perfect for high-volume production. Steel tooling is the ideal
choice for industrial applications where durability and consistency are the primary
concern. Another important thing to add is that steel molds are a perfect choice for
applications with very high tolerance requirements.

Generally, the typical tolerance that steel molds offer hovers around +/-0.002”, which
is quite impressive. However, using techniques like making the mold steel safe and
allowing adjustments to the mold to creep up on the tolerance can improve that
number even more.

Injection Tooling And Molding - 18

There are some drawbacks of steel molds as well. The most important of them is the
fact that steel molds have extremely high lead times and initial costs. This may be a
dealbreaker for a lot of projects as higher lead times mean lost opportunity costs and
less time to get ahead of the competition.

Steel Alloys used to make injection molds: 420, NAK80, S136, 316L, 316, 301, 303, 304

Stainless steel variants used to make injection molds: 420, NAK80, S136, 316L, 316, 301,
303, 304

2. Aluminum Molds

Another common choice in the

industry is aluminum which presents
the best of both worlds relative to 3D
printed and steel molds. Aluminum
molds can either be for prototypes or
for high-volume production depending
on the application. For prototyping,
aluminum molds offer faster lead
times, which means that a part can be
ready in almost a week. However,
prototyping molds are not too durable
and can only handle about 2000
pieces before needing a replacement.

On the other hand, production aluminum molds combine the best characteristics of
aluminum with Masted Unit Die (MUD) inserts to address the durability problem as well
and can last for 10,000 or even 20,000 in some cases. If all the parameters are
consistent, the shorter lead time and the overall economics remain the same for
Aluminum. Thereby making Aluminum the perfect material choice for meeting the
dynamic requirements of the current industry.

Aluminum Alloys used to make injection molds: 6061, 5052, 7075

Injection Tooling And Molding - 19

3. 3D Printed Tooling Molds

This is the ideal choice for situations where speed is of the essence. Businesses rely on
3D-printed molds to test out new design iterations and field-test their concepts. 3D
printing is relatively easier as the computer does the majority of the work and caters to
even the most complex designs as well.

However, these molds have several limitations as well because of their material
properties and are only good enough for smaller, low-volume batches. For higher
production numbers, other options like steel and aluminum molds are a better choice.

Here are a few common materials that are used to make 3D printed tooling molds:

PETG (polyethylene terephthalate) PP (polypropylene)

ABS (acrylonitrile butadiene styrene) TPE (thermoplastic elastomers)

Nylon (a.k.a. polyamide)

Injection Tooling And Molding - 20

By the Number of Cavities
Another common way of distinguishing between the type of molds is through the
cavities they have. Generally, the choice is between either a single-cavity or multiple-
cavity mold depending on the application. Depending on the application, family mold
also becomes a viable choice but its use is fairly limited when compared with the
other types. Here’s what they are exactly:

Injection Tooling And Molding - 21

Single Cavity Mold

A single cavity mold is the most basic design where only one part is created per
injection cycle. It is often used in applications where costs are the primary concern or if
the machines with higher tonnage are unavailable. Single cavity molds are a viable
choice for smaller to medium production volumes, generally up to a few thousand
parts.

Multi-Cavity Mold

Multi-cavity molds have the capability of creating several parts of the same design in
one cycle. It’s ideal for projects where economies of scale are important and the
production volumes range from a few thousand to even hundreds of thousands.

Multi-cavity molds, however, are more complex to make and require machines with
higher tonnage. Thereby increasing the initial costs of the mold.

Family Mold

Family molds are special kinds of molds that allow the creation of different kinds of
parts in a single cycle and single type of mold. Technically, family molds are
technically the same as multi-cavity molds. However, the difference is in the type of
products.

Injection Tooling And Molding - 22

Injection Mold Surface Finishes
The finish needs to be perfect to give a complete look to any product. Furthermore,
aesthetics are not the only thing that’s important. An excellent product finish not only
affects the product’s outlook but also affects the product’s quality and longevity.

Regarding industry standards regarding surface finishes, the two most prominent
names that pop up are SPI and VDI finish. Here’s what you need to know:

Injection Tooling And Molding - 23

SPI Surface Finish

SPI, also known as Plastics Industry Association (PIA) , has four categories of surface
finishing, ranging from a glossy to a textured finish for your parts. SPI understands the
importance of a surface finish for a product’s aesthetics. Even a minimal difference in
the finish from the design concept can drastically influence the look and feel of a
product. Each category comes with three subcategories to accommodate
manufacturers and further allowable deviations.

– Glossy Finish

A glossy finish – or a grade-A finish – gives a smooth and shiny look to your product.
It’s also the most expensive finish you can get. Grade A finishing requires hardened
tool steel molds. By using various grades of diamond buffs, these molds are further
polished. For a glossy finish that shines, the product undergoes a finishing process that
gives it an unclear texture and allows it to scatter light. To achieve this, a fine-grain
buffing paste with a rotary buffing machine is the most common and quickest choice.

Grade A has three subcategories that are different in the extent of their glossy look and
cost. This subcategory includes:

Super High Glossy Finish (Grade A-1) High Glossy Finish (Grade A-2)

Normal Glossy Finish (Grade A-2)

Injection Tooling And Molding - 24

– Semi-Glossy Finish

Grade B is also known as a semi-gloss finish. This finish is excellent for removing
marks and scratches from machining and tooling. Best of all, it has a reasonable cost.
Usually, grade B finishing is produced by utilizing different sandpapers and a linear
motion application method.

Similar to grade A, a semi-glossy finish also has three different subcategories. The
difference exists in their cost and finishing method. It includes

Fine Semi-glossy Finish (Grade B-1)

Medium Semi-glossy Finish (Grade B-2)

Normal Semi-glossy Finish (Grade B-3)

Injection Tooling And Molding - 25

– Matte Finish

Both grade A and grade B finishing are usually expensive options that eventually
increase the product’s production costs. If you’re looking for more affordable options,
grade C – or Matte Finishing – is a recommended choice.

Matte finish is a popular and economical surface finish you can get for your product. It
is a stone finish that can easily hide marks and scratches from machining and tools.
The process involves polishing the product with a fine stone powder. This step is also
the first step for glossy and semi-glossy finishing.

Matte finish includes the following three categories

Fine Matte Finish (Grade C-1)

Medium Matte Finish (Grade C-2)

Normal Matte Finish (Grade C-3)

Injection Tooling And Molding - 26

– Textured Finish

The final SPI category you need to know about is textured surface finishing. Textured
finishing is used for both industrial and consumer products simply because of its wide
aesthetic appeal. Incorporating a textured finish on your product involves similarly
smoothing the product as a matte finish. After that, the product is dry blasted using
materials such as glass beads. The randomness of a dry blast creates a textured
surface finish.

Textured finishing is a reasonably cost surface finish that hides machining marks and
even gives a good holding grip for the product.

Injection Tooling And Molding - 27

VDI Mold Texture Finish
VDI is the most popular injecting molding surface finish. Developed by the Society of
German Engineers, the surface finishing standard is mostly followed in Europe and
Asia. Texturing finish is one way of applying patterns to the mold surface successfully.
This procedure gives you flexibility in the design phase, and the freedom to create a
unique final look for your parts.

To ensure the desired results, You need to consider the mold texturing finish during the
design phase. Mold texture is sometimes used in designs for practical purposes. The
right texture finish can also help conceal some obvious surface flaws on molding
material as well.

In some applications where you expect to handle a particular part frequently, this
surface finish can help. You can add features that can conceal fingerprint marks.
Similarly, there are other options like knurling using VDI texture to enhance the user’s
grip or to lessen friction-related part wear.

VDI differs from SPI because it uses Electrical Discharge Machining and is incorporated
within the molding machine. It is also flexible enough to be used with classical tools
utilized in SPI, such as grit and sandpaper, which is one of the major advantages of this
surface finish.

Injection Tooling And Molding - 28

Key Factors to Consider when
Selecting Injection Molding
Tooling is an integral part of the injection molding process as the final product and
shape depend on it. The right tooling can ensure both the durability of the product and
keep the process efficient. However, choosing the right kind of tooling for any injection
molding project is easier said than done. It all starts with considering the right
parameters and then finding the right balance between cost, performance, and speed.

Here are the 8 most important parameters for choosing the best kind of tooling for the
job.

Injection Tooling And Molding - 29

Project Scope

This is perhaps the most important parameter that determines the right kind of tooling
for a project. For example, consider a prototyping lab working on trying out new
designs. For such cases, the best choice would be rapid 3D printed tooling because of
the speed requirements or prototyping aluminum tooling for more demanding
applications.

Prototyping doesn’t focus too much on durability and other factors as the most
important requirements are better speed and lower costs. For such cases, another
choice like steel would not make sense.

Part Size

The next parameter that plays an integral role during the tooling selection process is
the part size. Obviously, larger parts would need separate specialty tooling. However,
smaller part sizes can give manufacturers more freedom to opt for a much cheaper,
yet equally effective alternative; insert molds.

Insert molds are quite popular in the industry because of their lower costs and higher
productivity. Rather than paying the full price of standalone tooling, businesses can
select insert-tools that fit under pre-existing bases. Thereby reducing waste and
plummeting the high costs associated with this stage of the process.

Injection Tooling And Molding - 30

Expected Volume

For industrial applications, economies of scale play an integral role in making

processes affordable. The expected volume can sometimes determine the course of

action. Whether it’s worth investing in durable tooling or opting for something that can

simply get the job done for the time being.

Generally, single-cavity tooling is commonly used for low-volume part manufacturing

because it’s more economical than multi-cavity tooling. However, multi-cavity tooling

can significantly lower part price at the expense of a higher upfront cost.

Material

The material plays an important part in determining the tool’s life because of wear

and tear. Lighter material choices like polypropylene don’t have a lot of effects on the

mold. However, other materials like nylon or anything else that contains abrasive

particles like glass have shorter lifespans.

The prevalent industrial standard is aluminum or steel tooling for 8000 to 12,000 pieces

while anything lower than that would be suitable for other types of molds.

Injection Tooling And Molding - 31

The Complexity of the Part
The geometry has a significant impact on the tooling parameters. Naturally, features
like cavities, undercut, and cores are harder to develop and translate to a significant
increase in cost. Moreover, complex shapes also need expertise and experienced
talent is not easy to find. For prototyping, 3D printing would work but replicating the
same with higher materials like steel can pose a problem.

Another important factor related to the complexity and geometry of the part is the
surface finish. Polish, texture, or any other feature require great control over the tooling
and not all options can deliver them. For applications where aesthetics and
functionality have an equally important role, the options for the type of tooling can
become even more limited.

In the simplest terms, the more complex a design is, the more resources and expertise
it will need. Naturally, this would also drive up the overall costs as well and might even
make the specific project unviable.

Injection Tooling And Molding - 32

Applications
Depending on the application of the product, both the durability of the tooling and the
product become important. Aluminum, for instance, can process a maximum of
20,000 parts while steel can take it up to 100,000.

One more important factor to mention is tooling maintenance. Constant maintenance

ensures that the tooling won’t fail and allows for a larger number of alternatives.

Available Time
Metal tooling can take anywhere between 6 to 12 weeks. Sometimes, that is too long
and forces you to opt for an alternative that is either readily available or requires less
time. Sometimes even at the expense of other parameters like quality and durability.

Project Budget
Another integral parameter is the overall budget of the project. Tooling for injection
molds is responsible for a significant portion of the overall expenses of the project.
While choosing the tooling, you always consider the overall budget and decide on the
material according to the initial capital requirements, the production costs, and the
overall budget of the project.

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Injection Tooling And Molding - 33

Plastic injection Molding
Materials

It’s difficult to say what the best material for plastic injection molding resin is. It entirely
depends on what the project requirements are. It’s essential to find the optimal
material with both the physical and technical characteristics suitable for a specific
application. Some of the most important factors include load, strain, stresses, and the
characteristics you need for your part. These factors include loads, strains, tensile
strength, and much more.

Finding the right material involves trial and error. It’s important to have a thorough
understanding of the internal structure of the material and conduct several field tests
to gauge the actual performance during application. The following section discusses
some of the most recommended material choices for injection molding.

Plastic injection Molding Materials - 34

Nylon (PA)

Nylon is a synthetic material and is

popular in the automotive industry. The

material is tough but not heavy. It’s also

far cheaper compared to producing

metal analogs.

Best of all, nylon comes equipped with

high heat and abrasion resistance. The

material boasts impressive noise-

dampening properties. Its abrasion-

resistant characteristics make it an ideal

choice for high-wear applications.

However, you should look at alternative materials if your application involves exposure

to water. Nylon Pa tends to absorb water. Similarly, sunlight and strong acids can

seriously damage the material as well.

As mentioned, nylon is usually used in the automotive industry for mechanical parts

such as bearings and gears. Fixtures, jigs, and snap-fit closures are also some

examples. Besides these parts, nylon’s applications also include toothbrushes,

electrical connectors, and medical implants.

Nylon has four primary grades, and each grade has different properties.

Nylon 66: Has a higher melting point and a greater resistance to acids

Nylon 11: Ideal for outdoor application as it comes with a high moisture resistance

Nylon 12: Lowest melting point and a relatively low water absorption rate

Nylon 46: It has an extremely high operating temperature and is usually used for

engine and transmission parts.

Plastic injection Molding Materials - 35

ABS

ABS – or Acrylonitrile Butadiene Styrene – is an engineering-grade thermoplastic. This

material is easy to mold because of its low melting point. It has multiple options with
different textures and finishing. Manufacturers can even use colorants with the
material. Best of all, ABS has high impact resistance.

Multiple characteristics make ABS a good material option. It is relatively inexpensive

compared to other material options, and its properties allow ABS to be used in a wide
range of applications.

However, ABS has a low sunlight resistance and is unsuitable for outdoor applications.
ABS’s characteristic of generating significant smoke is more problematic and makes it
a safety hazard for industrial applications.

You’ll usually use ABS during the production of electronic parts and components such
as phone adaptors and keyboards. While ABS might lack the ability to work properly
outdoors, it makes up for it by not conducting electricity. This property of ABS makes it
a valuable material for electrical devices.

Plastic injection Molding Materials - 36

POM

If you’re looking to replace metal for mechanical and automotive parts, POM is
exactly the material you need. It is a thermoplastic material known for its strength
and rigidness. The best property of POM includes its resistance to solvents such as
gasoline, motor oil, and more.

However, POM is vulnerable to certain acids, such as nitric acid. Moreover, failure to
ensure uniform wall thickness may cause the material to shrink. Giving POM a
cosmetic finish is difficult, as painting on the material is extremely difficult.

POM applications usually involve gears, fans, and automotive and electrical switch
components. Its low water absorption and chemical resistance properties make it an
ideal pick for outdoor and water-based applications.

Plastic injection Molding Materials - 37

Polycarbonate (PC)

Polycarbonate – or PC – is another excellent material that you should consider. PC has

top-notch optical properties and allows manufacturers excellent dimensional control.
Its predictable and uniform shrinkage comes backed by its toughness and high
strength. Best of all, its transparent coloring can be changed to your liking. If you’re
looking for strength and durability, PC plastic is the ideal choice. The material is 250
times stronger compared to the glass while remaining lightweight.

PC can maintain its color and strength for a long time. From diffusers to machinery
guards, PC is used for various applications. The only major drawback of PC involves
their high production costs. Manufacturing PC requires high-grade stainless steel,
which might not suit every manufacturer’s budget. The material is also not suitable for
food preparation or storage.

However, PMMA falters regarding its high cost compared to glass. It’s also easily
scratchable and can be stained with greases and oils. Acrylics are also unsuitable for
most industrial processes due to their low-temperature service point.

Plastic injection Molding Materials - 38

PTFE (Teflon)

PTFE is better known as polytetrafluoroethylene. The material has high corrosion

resistance and is often used in the medical and electrical industries. PTFE is also widely
utilized for long-lasting parts such as bearings and mechanical gears. Its high
corrosion resistance makes it an ideal container for chemicals and acids.

PMMA

PMMA – better known as Acrylic – is an excellent thermoplastic material with excellent

properties. It’s an ideal alternative to glass due to its low weight, excellent
transparency, and shatter resistance. Acrylic comes baked with high tensile strength
and a low absorption rate. Best of all, PMMA is ideal for outdoor applications as it
strongly resists UV rays and weather.

Plastic injection Molding Materials - 39

PVC
PVC is another option that
manufacturers can choose. PVC, short
for polyvinyl chloride, is a cheap and
lightweight green alternative material
that offers high tensile strength and
environmental resistance. You’ll often
find PVC usage in automotive parts,
windows, and so much more.

PEEK
If you’re manufacturing parts and components for medical applications, PEEK is an
ideal material choice for you. PEEK is ideal for a medical environment due to its built-in
resistance against gamma radiation and autoclaving. Moreover, this engineering
plastic has excellent mechanical properties and chemical resistance. PEEK
applications can also involve long-term liquid submersion.

Plastic injection Molding Materials - 40

High-Density Polyethylene (HDPE)

Manufacturers often use HDPE for

plugs, toys, and totes. That’s
because the material has
remarkable electrical insulator
properties. That’s not all; HDPE
characteristics include its natural
resistance against moisture and
chemicals.

HDPE is tough and is fairly cheap compared to other alternatives. It even has a lower
density than water, allowing the material to float. However, HDPE has low surface
energy and high shrinkage.

Polyethylene (PE)

Polyethylene has three main types: High density (HDPE), low density (LDPE), and
polyethylene terephthalate (PET). We’ve already discussed HDPE. LDPE, or low-density
polyethylene, tends to have similar properties as HDPE. They’re only different in terms
of melting point, transparency and hardness.

Polyethylene is the only commercial polymer that is selected as per its density. Why?
Because its density directly influences the properties of the material. While this isn’t
true for PET plastic, all three types of polyethylene share a resistance against moisture
and chemicals. PET is similar to LDPE as both materials are as transparent as glass.

PE plastics are the most commonly used plastic materials in the world. They’re used
everywhere: from plastic water bottles to toys, cables, and device components.

Plastic injection Molding Materials - 41

Polystyrene (PS)

Similar to PE, Polystyrene (PS) is a material renowned for its high optic clarity. There

are two types of Polystyrene (PS) currently used by manufacturers for injecting

molding: General Purpose Polystyrene (GPPS) and High Impact Polystyrene (HIPS).

GPPS and HIPS have several differences related to dimensional stability and

transparency. However, despite their differences, GPPS and HIPS are suitable for

injection molding. That’s because both types have uniformed shrinkage that can be

easily predicted.

Fiber and Additives

Companies use additives to enhance their properties if the material has all the needed

requirements except a few. For example, materials such as POM or PP plastic are

reinforced with fiber and other additives for better stability, strength, and stiffness. On

the other hand, additives for PC plastic tend to improve the material’s UV or Flame

resistance.

Plastic injection Molding Materials - 42

Injection Molding Design Guide
Apart from the tooling, material, and finishing selection, there is another integral
parameter that affects the overall quality of the results. The design! The injection
molding process comes with several limitations and the design needs to cater to them
in order to ensure success.

Here are a few design elements that engineers carefully deal with while designing any
part for injection molding.

Injection Molding Design Guide - 43

Wall Thickness

One of the most basic rules of injection molding design is to ensure that the wall

thickness remains consistent throughout the part. Inconsistencies in the thickness can

result in several issues down the line starting from mechanical defaults like stress

concentration and micro-cracks that propagate with time.

Furthermore, inconsistencies in the wall thickness can also result in shrink variability,

which can further create problems down the line. The most ideal scenario that experts

recommend is to minimize any variability in the thickness and limit it to a maximum of

60% in the cases where it’s unavoidable.

Injection Molding Design Guide - 44

Tolerances
Keeping the tolerances under control can ensure the perfect balance between cost,
time, and complexity. Naturally, greater precision would lead to greater costs and
complexities. Therefore, the design tolerances shouldn’t be more than what’s needed
to ensure cost-effectiveness and efficiency without compromising on functionality.

Part Geometry
Building on to the last point, the geometry needs not to be unnecessarily complex for
the injection molding process to deliver the best result. Naturally, complex designs
have a trickle-down effect where they increase the cost and effort needed for tooling
and then for the part production itself. Designs with a lot of cavities, cross-sectional
variations, and other intricacies become harder to process and may need more
resources, which can affect the viability of the product for the market or cause the
business to lose its edge.

Injection Molding Design Guide - 45

Draft
The draft is the inherent capability in the product design to facilitate ejection by
tapering one side in the direction of the mold opening. The part’s geometry and design
characteristics are the primary determinant of the ideal draft for the product.
Generally, recommended minimum draft of 1 degree for excellent performance, but 2
degrees can work wonders and should be selected wherever feasible.

Radii
During the design phase, the product can have either sharp edges or smooth, rounded
surfaces. However, smooth surfaces are almost always favorable because they allow
for better mechanical characteristics and easier production. The liquified plastic flows
relatively easier on rounded surfaces during production and the design also reduces
the overall stress concentrations, something sharp edges are notorious for.

Injection Molding Design Guide - 46

Undercuts

Undercuts are any feature or auxiliary that prevents the ejection of the part from a
mold after cooling. While undesirable, some undercuts become necessary because of
design considerations or the nature of the applications. Here are a few instances
where undercuts become necessary for any injection molding design.

Interlocking, snap-on/off features in any product

Side holes or other cavities for buttons and other similar features

Vertical threads or a barb fitting in the design

Since completely avoiding them is next to impossible, there are some ways to
minimize the impact of undercuts on the process itself. For injection molding with
undercuts, the best way to facilitate processing is to incorporate the part feature in
such a way that it remains perpendicular to the drawn line. Doing so is one of the best
solutions as it facilitates the ejection process without any compromise on the
fundamental design and overall functionality of the part.

Injection Molding Design Guide - 47

Gates

In the injection molding process, the gates act as a pathway for the molten plastic,
and designers need to add them at the most precise location to ensure the best
results. If the gate design is wrong, the part may become prone to many process-
related injection molding defects including but not limited to flow lines, sink lines, weld
lines, and many others.

Today, there are multiple types of gate designs like the edge, tunnel, and cashew
gates that are commonly used for the best performance of the product. Here’s a brief
table explaining the different types of gates along with their popular applications.

Gate

The gate ensures that no jetting or overheating happens during the process. When it
comes to gate design, you must take great care to ensure consistency and
performance at all times.

Injection Molding Design Guide - 48

 Gate Type Description

This simplest and most effective option is ideal for

larger parts that are not too complex. These gates
Edge Gates
are common for parts with consistent thickness and
isolate the shear stress.

Tunnel gates are on the parting line which simplifies

the post-processing by causing the gate to
Tunnel/Submarine Gate automatically eject. However, this choice is only for
designs with small to medium cross-sectional
areas.

This is the perfect choice for applications where

aesthetics play an integral role. Cashew gates are
just like tunnel gates but have a greater curve, which
Cashew Gate
hides the parting line below the exposed surface.
Moreover, the limitations of cashew gates are the
same as tunnel gates.

Oldest and simplest gates that are hardly used

Direct Sprue Gate across the industry. Sprue gates have high shear
stress and are only viable for single cavity molds.

These are an excellent choice for applications where

a large cavity and even material flow are important.
Diaphragm Gate Diaphragm gates are a common choice for
cylindrical and circular parts. However, they are not
viable for other shapes.

Injection Molding Design Guide - 49

Ejector Pins
DFM Analysis :

RapidDirect provides
Depending on the complexity and intricacy of a design,
DFM analysis for
the product might need a little more ‘push’ to separate
injection molding
from the mold. Ejector pins do exactly that but come
project. Our team
with a severe drawback as well. As they apply force to
evaluates the design's
eject the product, they are prone to leave unappealing
manufacturability,
marks on the part. This is an issue for all applications
identifies potential
but becomes more severe for cases where the
issues and suggests
aesthetics are equally important as the functionality.
modifications to

improve the design's

Nevertheless, it’s also true that the ejector pins are truly
performance and
necessary. So, the best course of action is to simply
reduce production
accept the marks as a necessary evil. However, that
costs.
doesn’t mean that they have to be so obvious that they

become a dealbreaker. Luckily, the location of ejector

pins is not pre-determined and designers can easily

Material selection
change them to ensure that any mark wouldn’t be at a

very prominent location.

Part geometry

analysis

Moldability

analysis

Cost analysis

Design

recommendations

Get DFM feedback by

uploading your design.

Injection Molding Design Guide - 50

Common Industrial
Applications of Injection
Molding
Plastic injection molding is an excellent choice for manufacturing parts used in the
aerospace, construction, IT, and food industries crucial to the applications at hand. To
best understand how common it is, take one example of the food industry. Most of the
packaging for hard products relies on injection molding to provide durable, yet flexible
protection.

Now, let’s have a look at some of the most common industries where plastic injection
molding is integral.

Common Industrial Applications of Injection Molding - 51

Automotive Parts

One of the largest industries in the world is the automotive industry. A lot of
automobiles these days use plastic components be it the body kits, fenders, or even
spoilers used for better aerodynamics.

All these parts are mostly produced using the plastic injection molding technique due
to the accuracy and strength it provides.

Let’s take an example of a car’s body and multiple parts where plastic components
improve the aerodynamic profile. Components made by this technique provide the
characteristics that reduce drag force on the vehicle. That’s why many famous
automobile companies use plastic injection molded components.

Common Industrial Applications of Injection Molding - 52

Medical Industry
When it comes to accuracy and sustainability, the medical industry is at the forefront.
There are very stringent guidelines for manufacturing plastic parts in the medical field.
For continued operations, manufacturers must abide by multiple production
standards as there are lives at stake and any lapse can lead to a possible fatality.

Similar to automotive parts, medical parts require proper chemical properties and
structural properties that can sustain higher temperatures for durability. Accuracy is
key in this case because mostly the components are either for implants or for crucial
surgical operations.

Plastic Injection Molding is an excellent manufacturing process because it provides

increased strength, flexibility, durability, and easier modification. All these qualities are
the key to carrying out crucial surgeries. Some common parts using this technique
include surgical room prep equipment, supports for fractures, surgical equipment, and
dentures.

Common Industrial Applications of Injection Molding - 53

Electronics
In micro-applications, plastic injection molding is widely used because it provides the
required precision and quality of components in electronic items. Computers, laptops,
and most small-scale electronics utilize the plastic injection molding technique for
their smaller components.

Most of the notable components include motherboards, ram holders, casings of small
computer parts that include RAM holders, and SSD encasements. The constricted
requirements of dimensions are the primary reason why injection molding products
are popular.

Common Industrial Applications of Injection Molding - 54

Aerospace Industry
When it comes to precision and
structural strength, the field of
aerospace has very strict guidelines.
These days, most airplanes have their
aerodynamic components produced
through plastic injection molding.
Seeing the boom in automotive, the
aerospace industry has shown a lot
of changing trends in following this
technique for parts production.

The products in the industry using injection molding range from large to small. Most of
the interior of seats and handles use ABS plastic, which has a certain grade that works
with additive manufacturing techniques.

Retail
Coming to the presentability of the
product of injection molding, then the
most popular application of this
technique is the parts used for
display purposes.

The biggest reason why these parts

use plastic injection molding is that it
provides the aesthetics and the
finishing integral for the application.

Common Industrial Applications of Injection Molding - 55

Household Items

The most common industry using

plastic injection molding for
manufacturing is household items.
Looking around the house, anyone
would surely find a lot of components
in modern household items of plastic
or resin material.

The most common industry using plastic injection molding for manufacturing is
household items. Looking around the house, anyone would surely find a lot of
components in modern household items of plastic or resin material.

Common racks, window holders, handles and even holders for cutlery now use this
technique. The core reasons why these components are being made through this
technique are:

Durability Quality

Finishing Aesthetics

In a household, most people want their house to look nice and use plastic components
that can ease their lives. Products made through this technique provide efficient
durability and exceptional quality which is why it is a booming industry. Previously,
metal components were being used especially for the kitchen which made things a bit
difficult due to rust problems and the noise.

Ever since plastic products took charge, household items are now using this technique
which just goes to show how common it is now. Exporters around the globe are now
setting up major production plants that would solely produce such components and
then supply them across the globe. China is an example, where a major chunk of the
economy uses plastic products made through this technique.

Common Industrial Applications of Injection Molding - 56

FMCG Industry

The FMCG industry relies heavily on the injection molding technique. For packaging
and coming up with aesthetic designs, FMCG companies use packaging components
that are effective in coming up with innovative designs for packaging that are
attractive to the customers as well. Apart from the aesthetics and finishing of the
components, the FMCG industry also needs to abide by strict regulations for
sanitization and safety.

Injection molding is quite capable of improving the overall quality of products without
major issues that might be affecting the requirements of being BPA-free, FDA-certified,
and other regulations. The most important regulation, in this case, is the non-toxic and
GMA-safe regulation that plastic molding can deliver.

Common Industrial Applications of Injection Molding - 57

Construction Industry

Following a trend of making innovative products, many construction companies use

products that assist their workers in maintaining the on-site progress through such

components. Architects usually use protractors and geometry items made from

injection molding. Here are a few reasons why these components are used:

They provide cost-effectiveness as their mass production is cheaper than metal

products

Durability and flexibility of products that are important in multiple construction

applications

The low weight of parts and components

Abiding by the quality standards of safety components

Some common products made from plastic injection molding utilized in construction

include safety helmets, safety pads, design components, and various hand tools.

Common Industrial Applications of Injection Molding - 58

Major Factors Affecting the
Cost of Injection Molding
Cost reduction is one of the most difficult parts of manufacturing and it can be
troubling at times for a manufacturer. Optimizing the overhead cost and the
manufacturing cost needs proper planning and balance of payments.

Let’s have a look at 8 crucial factors that can affect injection molding costs:

Major Factors Affecting the Cost of Injection Molding - 59

Material Cost
The core reason why injection molding costs can increase is due to the material cost.
At times, abiding by certain standards for a material requires the extra cost to keep
the product of top quality. For example, regular production might not be as costly as
production of FDA-approved material production, but it would cost more.

Mold Cost
Sometimes, this cost is a one-time expenditure that can generate multiple products
by re-utilizing the mold over and over again. However, this is not the case when it
comes to innovative products such as customized mobile protectors and custom-
made parts. The manufacturer would have to re-do the whole process of making the
mold which would increase the cost.

Labor Cost
This is a variable cost that varies according to the minimum wage and the amount of
time the labor needs. Cost for labor may increase due to external factors such as
inflation or an increase in electricity or other resources because then the wages would
increase which would ultimately impact injection molding costs.

Major Factors Affecting the Cost of Injection Molding - 60

Part Complexity
This primarily comes under the domain of mold cost as well because the more
complex the part, the higher the cost because then mold would need additional
resources. Furthermore, at times, a complex design might not yield a proper mold on
the first attempt which may increase more cost.

Mold Size
Molds also use specific material which is impervious to thermal stresses and can bear
pressure at a higher temperature. An increase in the mold size requires additional
material for manufacturing which culminates in an increase in injection molding cost.

Major Factors Affecting the Cost of Injection Molding - 61

Production Volume
The production volume is one area where you can play around because it might
increase or decrease the cost by making the right decisions. Mass production always
lowers the overhead cost and thus increase in the production volume would increase
profits and thus lower the costs and vice versa.

Here are a few tips on how to reduce injection molding costs:

Increasing the production volume can yield better results when it comes to the
overall cost and it would also generate more revenue.

Regarding the complexity of the part, it is essential to review the design before
signing up for the order to prevent any losses.

Mold cost is usually on the rise so you must make sure that an older mold can be re-
utilized or not.

Topology Optimization is a technique that optimizes the design of products. Using

this technique, the designer can easily identify the room for refining the design for
manufacturing. Thereby, lowering the cost of molding.

Major Factors Affecting the Cost of Injection Molding - 62

The One-Stop Solution for
Injection Molding Projects
Injection molding may sound like a relatively straightforward process but there is a lot
that can go wrong. The tough competition in the current industry doesn’t leave a lot of
room for errors and you to need to consistently remain on the lookout for opportunities
to get an edge over your competitors.

The team at RapidDirect has decades of experience doing exactly that! With global
exposure, RapidDirect is aware of any potential problems a project may have. Whether
it’s a prototyping project with under 1000 cycles or a mid-level design with under 5000
cycles or a high-end industrial product with 100,000+ cycles. RapidDirect is the way to
go.

QTY

0 1
No MOQ High Efficiency

Consistency and Injection Molding

High Quality Specialists

Furthermore, RapidDirect also has one of the most stringent quality standards in the
industry that ensure unmatched quality, consistency, and performance at the most
competitive rates. With advanced facilities, integrated DfM systems, and a completely
online design analysis process, RapidDirect has no equal in the industry for injection
molding and any other manufacturing need. It truly is a one-stop shop for everything
manufacturing.

The One-Stop Solution for Injection Molding Projects - 63

Make On-Demand Manufacturing

Easier, Faster

Room 407, Building F, Tianyou Chuangke

Industrial Park, Qiaotou Community, Fuhai Street,
Baoan District, Shenzhen, China, 518103

+86-0755-85276703

info@rapiddirect.com

www.rapiddirect.com