Plastic Injection Molding

Overview

Plastic injection molding is our core manufacturing service, delivering high-quality thermoplastic components for industries worldwide. With 50+ injection molding machines ranging from 60 to 800 tons, we handle projects from small precision parts to large automotive components.

Our 30,000 sqm facility produces over 10 million parts annually, serving automotive, medical, electronics, and consumer product sectors. We work with more than 100 material grades, from commodity plastics to high-performance engineered resins.

Injection Molding Capabilities

Parameter	Capability	Application
Clamping Force	60 – 800 tons	Electronics to Automotive
Shot Weight	30g – 5,000g	Small to large housings
Part Tolerance	±0.01mm – ±0.05mm	Precision to general
Cavity Count	1 – 128 cavities	Prototype to mass production
Annual Capacity	10+ million parts	High-volume manufacturing

🔧 Molding Process

Step 1: Material Preparation

Raw plastic pellets are dried and prepared according to material specifications. Proper drying prevents defects like splay marks and ensures optimal material properties.

Step 2: Injection

Molten plastic is injected into the mold cavity under high pressure (up to 2,000 bar). Our machines precisely control injection speed, pressure, and temperature for consistent part quality.

Step 3: Cooling

The plastic cools and solidifies in the mold. Optimized cooling channel design reduces cycle time and minimizes warpage. Cooling typically accounts for 60-70% of the total cycle time.

Step 4: Ejection

Finished parts are ejected from the mold using ejector pins or plates. Automated robotic systems handle part removal for high-volume production runs.

Step 5: Quality Inspection

Every batch undergoes rigorous quality checks including dimensional measurement, visual inspection, and functional testing. CMM inspection ensures ±0.002mm accuracy for critical features.

📦 Material Selection

We work with over 100 thermoplastic materials from leading suppliers like BASF, Bayer, SABIC, and DuPont:

Commodity Plastics

• PP (Polypropylene): Automotive parts, containers, living hinges
• PE (Polyethylene): Bottles, caps, chemical containers
• PS (Polystyrene): Disposable cutlery, CD cases, packaging
• ABS: Electronics housings, automotive trim, consumer products

Engineering Plastics

• PC (Polycarbonate): Transparent parts, safety glasses, electrical components
• PA6/PA66 (Nylon): Gears, bearings, automotive under-hood parts
• POM (Acetal): Precision gears, fasteners, mechanical parts
• PBT/PET: Electrical connectors, automotive components

High-Performance Plastics

• PEEK: Aerospace, medical implants, high-temperature applications
• PEI (Ultem): Electrical insulation, aerospace components
• PPS: Chemical resistance, high-temperature environments
• LCP: Miniature electronic connectors, high-frequency applications

🎯 Industry Applications

Industry	Typical Parts	Materials Used
🏥 Medical	Surgical tools, housings, disposables	PP, PC, ABS, PEEK
🚗 Automotive	Interior trim, connectors, under-hood	PA, PP, ABS, PC/ABS
📱 Electronics	Housings, connectors, components	PC, ABS, PBT, LCP
🏠 Consumer	Appliances, housings, packaging	PP, ABS, HIPS, AS

🔍 Quality Control

Our comprehensive quality system ensures every part meets specifications:

• First Article Inspection (FAI): Complete dimensional verification of first production parts
• In-Process Inspection: Regular checks during production runs
• CMM Measurement: Zeiss and Mitutoyo coordinate measuring machines (±0.002mm accuracy)
• Visual Inspection: Trained inspectors under controlled lighting conditions
• Functional Testing: Assembly fit, performance testing as required
• Material Certification: Full traceability from raw material to finished part

📊 Production Capacity

Machine Type	Quantity	Clamping Force	Applications
Small	15 machines	60-150 tons	Electronics, medical disposables
Medium	25 machines	200-450 tons	Automotive, consumer products
Large	10 machines	500-800 tons	Large automotive parts, appliances

🚀 Secondary Operations

We provide complete post-molding services:

• Trimming & Deflashing: Removal of gates and flash
• Ultrasonic Welding: Joining plastic components
• Pad Printing & Screen Printing: Logos, text, graphics
• Spray Painting & Coating: Decorative and protective finishes
• Assembly: Complete product assembly with inserts and hardware
• Packaging: Custom packaging solutions for shipping

💰 Cost Advantages

📈 Project Timeline

Phase	Duration	Deliverables
DFM Analysis	2-3 days	Design optimization report
Quotation	24-48 hours	Detailed cost breakdown
Mold Manufacturing	15-35 days	Production-ready mold
T1 Samples	3-5 days	First articles for approval
Production	7-15 days	Finished parts, inspection reports

🌍 Global Shipping

We export to 50+ countries worldwide with reliable logistics partners:

• Air Freight: 3-7 days for urgent deliveries
• Sea Freight: 20-35 days for cost-effective shipping
• Express Courier: DHL, FedEx, UPS for samples and small batches
• Door-to-Door: Complete logistics handling available