Custom plastic injection molding manufacturing Service Cost

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Plastic Molding And Processing

MIC-ZG is an international OEM manufacturer. We are ready for factory audits and video calls at any time.

From design to production. We provide feasibility analyses, market research and trial launch for each injection mold. We are committed to helping customers win the market in a real sense, rather than simply OEM plastic production. We will customize at least 3 solutions and offer you a $500 discount on your first mold.

Injection Moulding manufacturer in China

MIC-ZG is one of the professional Injection Moulding manufacturer in China. Complete specifications and high quality. We are committed to treating customers with integrity and quality, thus winning a group of loyal customers.

The principle of injection molding is to add granular or powdery raw materials into the hopper of the injection machine, and the raw materials are heated and melted into a flowing state. Under the push of the screw or piston of the injection machine, they enter the mold cavity through the nozzle and the pouring system of the mold, hardened and shaped in the mold cavity. Factors affecting the quality of injection molding: injection pressure, injection time, injection temperature.

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At MIC-ZG, we first review your submissions and then negotiate with you to ensure that your specifications, delivery times and prices meet your project needs. We then use your 3D part data for CNC machining of high quality injection molds. After the mold is created, MIC-ZG will send you a sample to confirm the details. Once the molds have been improved and approved, MIC-ZG begins production.

What are the advantages of injection molding

1. Short molding cycle, high production efficiency, and easy automation

2. It can form plastic parts with complex shapes and precise dimensions, with metal or non-metal inserts

3. Stable product quality

4. Wide range of adaptation

What are the plastic molding methods that we are good at

Plastic molding is the most cost-effective method of mass manufacturing plastic parts. The forming process is to add the material to the mold and quickly the product is formed. This process is rapidly repeated between tens of thousands and a hundred million times. We apportion mold cost to each product and make the mold cost down to a dollar per piece, or even free. Because plastic molding uses the same mold for each part, the process provides consistent quality for each part. Plastic molding also offers the widest variety of materials, colors, polishing methods and surface textures compared to CNC machining or even Injection Molding.

MIC-ZG Plastic Molding service is a highly customized service offering on-demand prototyping and production molding. We will customize at least 3 solutions for you, including the most affordable plan and the one that best meets your needs.

From design to production. We provide feasibility analyses, market research and trial launch for each injection mold. Our team has rich experience in various industries. From retailers to the Fortune Global 500, our customers come from all over the world. No matter where you are from, we are all friends. First-time buyers can get a $500 discount on their first mold of MIC-ZG.

If you want to know more, please see " Mold Surface Strengthening Technology"

What is the injection molding process

The injection molding process can be simply expressed as follows: Last cycle - mold closing - filling - pressure holding - glue back - cooling - mold opening - demoulding - next cycle

In the filling and holding pressure drop section, the cavity pressure increases with time. After filling the cavity, the pressure will remain in a relatively static state to supplement the insufficient amount of glue due to shrinkage. In addition, this pressure can prevent injection. The phenomenon of colloid backflow caused by the reduction is the holding pressure stage. After the holding pressure is completed, the cavity pressure gradually decreases, and can theoretically drop to zero over time, but it is not actually zero. Therefore, after demolding, the internal stress of the product is stored, so some products need to be post-processed to remove residual stress.

Injection Molding Capabilities

MIC-ZG shapes a variety of products and parts, from the smallest medical plug-ins to large automotive, aerospace and defense parts.

Service	Details
Service Lead Time	Details Delivery within the agreed time.
Service Production Options	Details Made in China
Service Materials	Details Most plastics
Service Machines Available	Details Machines in Taiwan, Germany, America, Japan
Service Inspection and Certification Options	Details AAA,CE,SGS,Intertek,ALIBABA,MADE IN CHINA
Service Tool Ownership	Details MIC-ZG charges the cost of mold manufacturing, and the ownership right belongs to the customer. After the contracted number of OEM production, MIC-ZG refunds the mold fee to the customer.
Service Mold Cavity Tolerances	Details +/- 0.0005 inches
Service Part to Part Repeatability	Details +/- 0.0005 inches or less
Service Critical Feature Tolerances	Details Tighter tolerances can be required, up to +/- 0.0001 inch tolerances, increasing tooling costs.
Service Available Mold Types	Details Steel and aluminium; MIC-ZG is typically produced in quality grades that can be recycled from 100,000 to 100 million cycles.

This table describes some details of MIC-ZG injection molding services.

Injection Molding Capabilities

When tooling, the typical tooling tolerance is +/- 0.005 inches. MIC-ZG mold processing tolerance is +/-0.0005 inches, ten times better than the industry standard.
A tighter tolerance can be required. MIC-ZG can achieve a minimum machining tolerance of +/- 0.0001 inch, which is 50 times better than the industry standard. This will increase the cost of processing. MIC-ZG technology can meet the tolerance requirements of the world top 500.
MIC-ZG can adjust hardness and toughness according to customer's requirements.
The standard of repeatability between parts is much higher than the market standard and can pass any test.
The stipulated time of delivery applies to samples. We will inform you in advance of the production time after the sample confirmation.
The initial sample shipment quantity is 1 piece, but it may change due to its size, color, material, process or customer's requirements.
MIC-ZG guarantees a perfect color match for each Pantone color.
All quotations are based on sufficient manufacturability of the design.
Unless explicitly discussed, core, ancillary operations, and tool strategies are determined by MIC-ZG.
Unless explicitly discussed, gating, ejection, knit lines and parting lines are at the discretion of MIC-ZG.
Unless explicitly discussed, the portion not proposed by the client is at the discretion of MIC-ZG.

If you want to know more, please see "Quality Control Data(Part of)"

Plastic Molding Material

Below are the most common materials. If you cannot find the material inventory you are looking for, please specify features, tolerances, characteristics, and quantities. Please feel free to contact us as soon as possible. Our experts will conduct engineering review. MIC-ZG can also use resins purchased or provided by customers for production projects.

Manufacturing elastomeric parts can be accomplished by injection molding, RTM or compression molding.

Our team can help you determine the best method based on part geometry, estimated annual production and the type of material required.

Rigid plastic materials:

ABS (acrylonitrile butadiene styrene): High-strength general-purpose engineering plastic, used for many commercial products.
ASA (acrylonitrile styrene acrylate): A material very similar to ABS with higher resistance to fading and better suited for outdoor use.
CA (cellulose acetate): Typically used in eyeglasses and film, CA is a flexible clear material that can be used in food contact.
HDPE (high-density polyethylene): Excellent strength-to-weight ratio and chemical resistance. It is often used for fuel tanks, connector insulators, and food containers. HDPE is also used in outdoor equipment like playgrounds.
LCP (liquid crystal polymer): LCP has mechanics even at elevated temperatures as well as low dielectric constants. This material provides exceptional features for micromolding and thin walled components. LCP is popular for electrical connectors and interconnects as well as medical devices.
LDPE (low-density polyethylene): A flexible and tough material with lower density versus HDPE. LDPE does not react to acids, bases, or alcohols. Useful for trays, snap lids, and general-purpose containers.
PA 6 (polyamide 6, nylon 6): Offers increased mechanical strength, rigidity, good stability under heat, and/or chemical resistance.
PA 6/6 (polyamide 6/6, nylon 6/6): Offers increased mechanical strength, rigidity, good stability under heat, and/or chemical resistance.
PARA (polyarylamide): Often combined with infills such as glass or mineral fibers, PARA creates very rigid parts with low creep and a slower rate of water absorption compared to nylon (PA). PARA is great for structural components in handheld electronics as well as medical devices.
PBT (polybutylene terephthalate, Valox): A common electronic insulator with a polyester base. Highly used in automotive as a longer-wear alternative to nylon.
PBT-PET (polybutylene terephthalate-polyethylene terephthalate): A compounded blend of PBT and PET.
PC (polycarbonate): A clear or colored, lightweight, glass-like plastic that is heavily used across multiple industries. PC is impact resistant, holds great feature detail, and can be used for safety equipment, lenses, electronic devices, and much more.
PC-ABS (polycarbonate-acrylonitrile butadiene styrene): The best of both PC and ABS. Higher-strength engineering thermoplastic with slightly more flexibility than standard polycarbonate.
PC-PBT (polycarbonate-polybutylene terephthalate, Xenoy): A tough and rigid material resistant to lubricants, solvents, and cleaning agents. Very common in electronic enclosures.
PC-PET (polycarbonate-polyethylene terephthalate): A blend of PC and PET provides tough and chemically resistant results and can be used as an alternate to PC-ABS. It endures harsh solvents and cleaners, making it excellent for sports equipment and healthcare applications.
PCT (polycyclohexylenedimethylene terephthalate): A thermoplastic polyester that typically outperforms PET due to lower moisture absorption and better environmental stability. PCT is often used for connectors and switches.
PE (polyethylene): One of the most common plastics used in the world, PE has high ductility, abrasion resistance, and chemical resistance. PE is often described by its molecular weight, such as UHMW PE (ultra-high molecular weight), LDPE (low density), or HDPE (high density). PE is used in packaging, tubing, films, bottles, and more.
PEEK (polyether ether ketone): Offering excellent tensile strength that surpasses most plastics, PEEK is often used as a lightweight substitute for metal parts in high-temperature, high-stress applications. PEEK resists chemicals, wear, and moisture.
PEI (polyetherimide, Ultem): Known best for its extremely high heat and flame resistance, PEI is used for many medical applications and is more affordable than PEEK.
PE-PP (polyethylene-polypropylene): A resin blend of the polyolefin's polypropylene and polyethylene.
PE-PS (polyethylene-polystyrene): A resin blend of the polyethylene and polystyrene.
PES (polyethersulfone): A rigid, transparent plastic that is chemically inert, biocompatible, and sterilizable. PES is suitable for food-contact devices such as coffee machine components as well as aerospace and automotive where chemical exposure is high.
PET (polyethylene terephthalate, Rynite): Also abbreviated PETE, this is a clear, strong, and lightweight PE resin heavily used in food packaging, soda bottles, jars, and more. The material is food-safe. PET is recyclable with a resin code of 1.
PLA (polylactic acid): A biodegradable and renewable plastic. PLA has a relatively low glass transition temperature and is common in short-use applications.
PMMA (polymethyl methacrylate, acrylic): A clear glass-like plastic. Good wear and tear properties. Great for outdoor use.
POM (acetal polyoxymethylene, Delrin): Good moisture resistance, high wear-resistance, and low friction.
PP (polypropylene): Polypropylene has excellent electrical properties and little or no moisture absorption. It carries light loads for a long period in varying temperatures. It can be molded into parts requiring chemical or corrosion resistance.
PPA (polyphthalamide): A subset of nylons (polyamide) that typically exhibit a higher melting point and lower moisture absorption. PPA is typically used in automotive and industrial applications due to its ability to withstand harsh chemicals. PPA is good for fuel and fluid manifolds and headlight housings.
PPS (polyphenylene sulfide, Ryton): A high-performance thermoplastic with extreme resistance to solvents.
PS (polystyrene): A clear, hard, and brittle material widely used for food packaging, clamshell containers, and even disposable cutlery.
PS-PPE (polystyrene-polyphenyl ethers, Noryl): Exhibiting high heat and flame resistance, PPE-PS has high stiffness and tensile strength even at elevated temperatures.
PSU (polysulfone, Udel): A rigid, stiff, and transparent plastic which is a higher-performance alternative to polycarbonate.
PVC (polyvinyl chloride (Shore D)): A rigid, general-use plastic that is common in plumbing, non-food packaging, and trimming.
PVDF (polyvinylidene fluoride, Kynar): A chemically inert, high-temperature material. Due to its low friction, PVDF is used in plumbing parts, bearings, chemical handling, electrical wire insulation, and tubing.
SAN (styrene acrylonitrile): A polystyrene that is heat resistant and transparent. Due to its relationship with polystyrene, SAN is low cost and has enhanced clarity and shine. SAN is common in household goods, door handles, and kitchenware.
TPO (thermoplastic polyolefin): A flexible plastic with good chemical resistance but lower temperature resistance compared to PP.
TPU (thermoplastic polyurethane (Shore D)): A tough, highly abrasion-resistant resin that bridges the gap between rubbers and plastics. TPUs can be formulated to be rigid or elastomeric. TPU exhibits a high flex before break and is ideal for wheels and door panels.

Elastomer/Rubber molded materials:

EPDM (ethylene propylene diene monomer rubber (Viton)): One of the highest performing rubber elastomers with high heat resistance, chemical resistance, and moisture sealing properties. EPDM is commonly found in automotive seals, gaskets, O-rings, and electrical insulators.
PEBA (polyether block amide): A soft, flexible, plastic or elastomer used for medical devices such as catheters. PEBA foams are used for padding, shoe insoles, and sports equipment. PEBA is resistant to moisture and UV exposure.
PVC (polyvinyl chloride (Shore A)): A rubber-like, general use elastomer, that is common in outdoor products, protective films, and mats. Shore A rubber-like PVC requires plasticizers to improve its flexibility from its typical rigid state. PVC is flame retardant due to self-extinguishing properties.
TPE (thermoplastic elastomer): A broad class of elastomers that behave like a thermoset with high flex and elasticity but process like a thermoplastic through molding. TPE is an umbrella term for many unique elastomer classes.
TPU (thermoplastic polyurethane (Shore A)): A tough, highly abrasion-resistant elastomer that bridges the gap between rubbers and plastics. TPUs can be formulated to be rigid or elastomeric. TPU exhibits a high flex before break and is ideal for flexible tires, skateboard wheels, and weatherproof gaskets.
TPV (thermoplastics elastomer, vulcanized rubber (Santoprene)): An excellent elastomer with high versatility due to temperature resistance, compression, and elasticity.
LSR (liquid silicone rubber): Offering food and biocompatibility, extreme heat resistance, and excellent flexibility, silicones are a versatile rubber material. LSR is used for medical devices and automotive, aerospace, and consumer products. Liquid silicone rubber molding is a specialized process different from traditional injection molding.

If you want to know more, please see "Plastic Molding Finish"

Guide to Injection Molding Design

The influence of the design of filleted corners of plastic parts on mold cost

>in the process of mold testing, the position of the buckle on the plastic product will appear fracture after the production of dozens of products, resulting in mold testing interruption. Mold assembly personnel often remove the mold to clean the broken buckle.
The main reasons for buckle fracture are as follows: stress concentration occurs in buckle parts during injection molding; The side moulding Angle of the buckle is not enough.
If you only solve the problem from the mold side, it is polishing and polishing. And for the problem of the broken buckle, it is a phenomenon that cures the symptoms but not the root cause.
Repeated mold testing will result in the increase in mold testing cost, mold polishing and assembly workload and manufacturing costs.
During mold processing, fillets or corners need to be processed by EDM to meet the shape of the plastic parts.
If the plastic parts are designed with reasonable fillets in the corner, the discharge machining process and related discharge machining materials can be reduced, and the mold processing cost and processing time will be significantly saved.

Influence of wall thickness design of the plastic parts on mold cost

Wall thickness of plastic parts is an indirect impact on mold cost.
We analysis and discuss mainly from two aspects:
① If wall thickness is too thin, plastic parts are prone to lacking glue, while causing plastic parts production instability, increasing the cost of mold testing cost;
② If wall thickness is too thick, plastic parts are prone to shrinking, and the plastic parts will have different degrees of deformation. In order to solve these problems, the cooling time in the injection molding cycle will be increased to reduce the defects of the plastic parts.

The change of plastic parts design

Plastic parts designers need to understand the mold knowledge as much as possible, so that the design of plastic parts can meet the feasibility of mold processing, reducing the mold manufacturing difficulty and cost.
Timely communication among product development department, mold manufacturing department and injection molding department will be of great help to reduce the cost of plastic parts.

The rationality of mold design

The work experience of mold designers varies. Their design levels are different. In order to solve the problems in the design process, the most effective way is to carry out plastic parts and mold review.
For example:
1.To avoid the labor cost and mold testing cost caused by design defects. In many cases, it is not possible to compensate for mold design defects by adjusting the molding process parameters. This will cause great losses, including but not limited to time cost, labor cost and mold trial cost.
For products with different quantity requirements, mold design corresponding to mold life should be adopted to avoid customer's cost loss.

Purchasing of standard parts

In order to reduce the mold cost, standard parts need to be used as much as possible during mold design.
The ability to meet the specifications of multiple standard component suppliers is preferred. We can choose several suppliers to compare prices when purchasing.
More choice space is conducive to reducing mold costs.

Reduce the times of mold trials

In order to meet the delivery time and price required by customers, we must standardize the times of mold trials. Reasons for too many times of mold trials:
(1) The mold was designed without sufficient collective review. The structure of the mold is unreasonable, so that the mold has to be improved for many times after the mold testing;
(2)The mold design is very good, but the mold processing is not up to standard, so that the times of trials increase gratuitously, Increasing the mold cost;
(3) The best molding process and injection molding machine is not selected during the mold test. The mold is well made, but the plastic parts produced by injection molding are not ideal;
(4) The physical properties of plastics are not fully understood. Shrinkage rate is not accurate, resulting in repeated mold repair.

Mold materials

Not only mold costs need to be reduced, but also customer's requirements of the product surface gloss need to be met.
We advise customers to choose cheap materials for processing and the surface coating treatment to be carried out on the surfaces of the mold cavities to improve the gloss, anti-rust ability and abrasive resistance of molds.

Factors of Injection Molding Production

During each processing, we need to add new raw materials.
If there is a problem with the mold during the manufacturing process, we often need to repair the mold, which will take at least a few days.

We have to wait for the next molding time and re-add raw materials.

Maintenance of mold , waste of raw materials, downtime of injection molding machine.

All these cost traps will eventually lead to increased costs.