Injection molding

The process

Injection molding (also known as injection molding or injection molding process) is a primary forming process used to generate 3D objects from e.g. plastic or metal by injecting a material into a cavity. Injection molding allows components to be produced automatically and in a short time with very high reproducibility. The surface of injection-molded components can be selected almost freely depending on the application and requirements. This means that particularly smooth surfaces can be produced for applications with high aesthetic demands, as well as internal components without special preparation of the mold cavity. Injection molding is particularly suitable for medium to large series due to the start-up costs incurred by the necessary mold production, but small series can also be realized economically for simple geometries.

What is required?

The manufacturing process

What are the limitations?

The greatest restrictions in injection molding are the demoldability and the warpage of the component. Compared to 3D printing, the limit of design freedom is therefore somewhat lower for this manufacturing process. Injection molding is characterized by its accuracy as well as the special degree of precision, with simultaneously excellent material and surface properties, very high reproducibility and enormous speed for high quantities.

The advantages of injection molding

• Cost-effective manufacturing process for higher volumes
• Processing of series materials
• Components do not have to be reworked or only slightly reworked
• Fully automatable process
• Very high precision and excellent surface finish
• Forming process from raw material to finished part in one operation

Application areas injection molding

Injection molding is one of the most common manufacturing processes for the production of plastic components in large quantities. With the help of a specially manufactured negative mould, the injection moulding tool, components can be produced at very short intervals and with high precision and quality. With the decades of experience of our experts, both in injection moulding and tool making, we support you competently and reliably in the realisation of your product.

Small series/ prototype series

Injection molds made of aluminum are particularly suitable for the injection molding of components in small quantities, for example for small series or prototypes. These tools, made of comparatively soft metal, can be produced much faster and more cheaply than tools made of steel. At the same time, the tools have a much shorter service life, so they need to be replaced more quickly. Usually for an aluminum tool are about 10.000 – 20.000 shots (the number of fillings of the mold with plastic). Tools with more than one component per mould are also possible, so-called multiple tools, so that the number of producible components per mould can also be well over 20,000. Decisive factors here are primarily the complexity of the component and the plastic used.

Medium size series

The injection molding production process is particularly suitable for the manufacture of components in large quantities. The comparatively high start-up costs for the injection mold can therefore be spread over as many components as possible, so that a economies of scale are quickly achieved and the unit costs remain low.

Tools made of steel are much more resistant than aluminum tools and withstand the stresses of production for much longer. Output quantities of several hundred thousand to millions of components are common. We manufacture your mould precisely and reliably, always in accordance with your individual component.

Large series and Highrunner

The productivity of the tools is an important factor in the injection molding of large series. Decisive for the productivity of the process are minimum cycle times and the highest possible output of the mould. By combining traditional toolmaking with additive manufactured tool steel inserts, the efficiency of the injection molding process can be maximized. The 3D-printed inserts can be provided with cooling channels close to the mold contour to optimize the temperature control of the mold and the hot plastic melt. In this way, cycle times can be reduced and the number of injection molded parts increased. Our experts will be pleased to support you in the optimal design of the individual production process.