Advanced injection molding processes extend the capabilities of traditional injection molding, often allowing for more complex geometries, material combinations, or improved production efficiency. While traditional injection molding is a great, versatile manufacturing option, there are some advanced injection molding processes that may better suit the needs of your project.
Advanced Injection Molding Manufacturing Processes
Overmolding
This process involves molding one material — typically a softer, more flexible one — over a previously molded substrate, which is often a rigid plastic. This technique creates parts with multiple material properties, improved grip, and aesthetic enhancements. Overmolding can be used to help improve the ergonomics of a product and apply flexibility to rigid parts.
Stack Molding
Stack molding produces multi-level injection molded parts through stacked mold faces. This allows for multiple pieces to be produced at one time during the same injection molding cycle on the same machine, greatly improving productivity. Stack molding is typically used for mass-consumption parts, but also supports other applications, such as products with complex shapes.
Hot Runner Molds
Hot runner molds optimize cycle times and minimize material waste. It is often used within an injection mold to help bring the molten plastic from the barrel of the injection molding machine into the cavities of the mold. This allows for the processing of a wider range of resins and makes sure the resin maintains the ideal temperature continuously throughout the mold.
Insert Molding
Insert molding integrates metal or other inserts for enhanced strength or functionality. The insert is loaded into the mold where it is then overmolded with plastic to create a part with improved functional or mechanical properties.
Highly Intricate Tooling
Intricate tooling produces parts with complex geometries and tight tolerances. This type of tooling allows manufacturers to tackle the most demanding of projects without the worry of achieving the necessary level of quality.
Multi-Cavitation Tooling
Multi-cavitation tooling increases production efficiency by creating multiple parts per cycle. This tooling includes considering the gate, side actions, pick-outs, size, and geometry.
Uses of Advanced Injection Molding Processes
Overmolding
Overmolding is used in many industries to create comfortable and reliable products. This process is commonly used in the medical industry to create devices that require soft ergonomic grips and handles with a sturdy base and wearable medical devices, providing comfort and reliability. The automotive industry also uses overmolding to create engine covers, headrests, armrests, driver controls, seals, sensors, and electrical connectors. Another industry that uses overmolding is electronics, using it to create plastic casings with an ergonomic feel and wearable electronic components that require a combination of flexible and rigid parts.
Stack Molding
Stack molding is commonly used to create consumer goods and medical products. This manufacturing process is used for thin-walled containers, lids, closures, and caps for a range of consumer goods. In the medical industry, stack molding is the chosen process for parts that require two levels or materials, such as valves and implantable components.
Insert Molding
Insert molding also has many applications for critical industries, including aerospace, automotive, medical, and electronics. For the aerospace industry, insert molding is used to manufacture interior components, communication, and control applications. These products reduce the weight of the aircraft while improving the strength and durability of the components at a reduced cost and timeline.
The automotive industry often uses insert molding to replace metal parts with durable, lightweight plastic ones. This makes vehicles lighter in weight and more affordable while still offering the durability and safety needed.
Medical equipment is often created through insert molding. This includes tubing, medical equipment components, dental instruments, prosthetics, medical knobs, blades, surgical instruments, and medical enclosures.
The electronics industry commonly manufactures encapsulation of threaded inserts and wire plugs, digital control panels, and knobs for appliances through the process of insert molding.
Explore Quickparts’ Advanced Injection Molding Processes
At Quickparts we have decades of experience in injection molding, including many advanced processes, such as overmolding, insert molding, stack molding, and much more. When you work with us, you will experience all of the benefits of an experienced injection molding partner.
Our team will first conduct a Design for Manufacturing review so your products are designed efficiently for your chosen manufacturing process. We have a streamlined approach to designing and manufacturing your tooling, reducing the cost and time it takes to get your project started. Plus, with our best-in-class equipment, we can meet the most demanding requirements.
Are you ready to experience quality end-to-end supply chain visibility? Contact our team today to get started.
