Many plastic manufacturers are taking a proactive approach to meeting their customers' needs for rapid delivery of plastic molded parts. At the same time, the advantages of small batch production play an important role in plastic molding. The production of plastic frames in small quantities requires the use of several available manufacturing processes. According to the number of elements you specify, which can only be used as pre-drain, small batch injection molding can be used to produce real injection molding parts.
Discover that our rapid injection molding is a great option for small batches of parts up to 100,000
Plastic Injection Molding
Also known as low-volume plastic molding, it is the very rapid production of parts with high quality and precision. It is the preferred method for producing large quantities of finished plastic parts for industrial and commercial use. The molten resin is placed under high pressure in the chamber of a metal mold, where it is immediately cooled to form a solid mold. A single operation to produce a complete part can take anywhere from a few seconds to minutes, depending on the complexity of the part and its size.
Plastic Molding Process for Small Quantities
Before starting plastic injection molding, you must first have all the necessary tools for this process. All steps must be followed to ensure you receive an accurate final product. In the first stage, the plastic resin, which is in the form of raw granules, is dried until it reaches the correct moisture content. It can then be mixed with masterbatch hues or colors if necessary. In the next step, the dried granules are poured into the bowl of the casting machine.
An interchangeable screw located in the machine's bowl moves these granules toward the mold. The third step involves mixing and heating the solid particles contained in the cylinder to a point where they completely melt and form a liquid resin. The now heated mold closes spontaneously and the resin, which is under enormous pressure, is introduced into the mold chamber through an opening. The mold is then cooled to harden the inside. It then opens and the piece is removed to start a new series.
Injection molding in small quantities
Also called prototype injection molding, it is used in the production of injection molded parts depending on the quantity required, which can only be used in a single run. This design is ideal for off-the-shelf prototypes, bridging tools, and small series. Small batch plastic molding can also be used to produce small quantities of plastic parts. Different companies use this process to produce parts depending on their quantity needs.
When it comes to small batch injection molding, you first need to upload your 3D computer-aided design file to quickly get a mold. Once your design is uploaded, modeling and processing takes place. Engineers can evaluate models to ensure you receive a model that meets your specifications. Once engineers approve your design, construction of an injection mold begins. You have time to check your sample and give the green light. After all these procedures, production of the parts begins.
Methods for producing plastic moldings in small quantities
The other three alternative technologies that can be used in manufacturing low-volume plastic molding include compression molding, structural foam, and reaction injection molding.
Pressure formation
Commonly called vacuum forming or thermoforming, it involves applying a hot layer of plastic to a hollow or elongated tool. The material is first stretched, a vacuum is passed through the special device, after which pressure is applied to the back of the layer to fill the chamber into the desired shape. After creation, excess materials from already formed parts are cut off on a CNC cutting machine.
Reaction Injection Molding
In this type of rapid injection molding, a liquid thermoset is infused, which is then mixed under minimal pressure. The material structure is rigid and dense, and various types of reaction injection molding materials have been developed for specific applications. Reaction injection molding typically uses an epoxy-aluminum complex, which is cheaper and can be used for a large number of injection passes. The underlying substance can be colored in order, but cosmetic parts must be painted and sanded. Reaction injection molding is best suited for solid plastic parts with sophisticated details.
Structural foam
It is a molding process that begins with a short infusion of resin and then uses natural or synthetic blowing force to build up the mold material. The final part has a closed cellular structure inside, but a hard outer skin. As the mold is filled, bubbles burst forming a sinuous appearance on the outer surface. Sanding and painting are excellent ways to remedy this effect. You can also make other improvements to the tool. Structural foam is cheaper and you will have a smoother molding time compared to other methods.
Advantages of plastic molding in small quantities
- Cheaper mold cost : Small volume molds are usually cut from high-quality plastic, which is easier to machine and modify.
- From product to market : Requires only a modest investment, allowing the product to reach the market faster. Furthermore, the financial loss will be less if a new product is not successful in the market.
- Tools : Low-volume tools can extend product life if you update products frequently during product development.
- Low volume advantages Most of the time, only a few thousand parts are needed to cover all pre-production and manufacturing needs until the transition to mass production.
Advantages of small series production
Manufacturing small quantities offers the following advantages:
1. Cheaper. Compared to large-scale production, it is more economical. This is because there are minimum order quantities, which means tooling costs are lower.
2. Fast processing. You also benefit from short lead times when producing your mold. This allows you to get your products to market faster and gain quick access to emerging markets.
3. Reduced investment risk. Additionally, your designs can be revised faster and brought to market seamlessly compared to large-scale production.
Therefore, low-volume production is becoming an increasingly popular option for many product variants, as it provides scope for more targeted investments in production and materials, whilst also enabling rapid market reach and a quick response to the limited shelf life of products. It also serves as a link between original prototypes and high-volume production, especially for small-volume plastic injection molding projects.
Low Volume Plastic Injection Molding Process
In China we have great advantages in relation to producing small quantities. We are experienced in producing small quantities of plastic molds and are particularly specialized in complex plastic injection molded parts in small quantities. From simple to complex plastic molded parts in small quantities, each customer's needs are always our top priority. We would now like to tell you more about our techniques for manufacturing injection molded parts in small quantities so that you can make your project more successful.
Stay at the heart of our business
- The objective is to build a more flexible and effective management team for the production of plastic molds
- Short delivery times
- Quick tool change
We are good at kinds of plastic frames
Through these methods we can help you carry out the production of complex plastic parts.
- Overmolding
- Large pieces
- Insert template
- Microforming
We process thermoplastics
We are also trying to introduce more types of thermoplastics to meet the needs of all customers around the world. Therefore, it is extremely important to understand your production material choice for small volume plastic parts.
- Polyetherketone (PEEK)
- High-density thermoplastics (Gravi-Tech
) - Antimicrobial products for the food industry
- Polyphenylene sulfide (PPS) materials (Fortron® or Ryton®)
- Polysulfone (PSU) materials (Udel®)
- Polyetherimide (PEI) materials (ULTEM
) - Polyphenylsulfone (PPSU) materials (Radel®)
- Thermally conductive plastics
