Injection molding is one of the most common forms of manufacturing that is perfect for low-volume manufacturing of end-use parts, bridge tooling, and prototyping. The whole mechanism of the process is based on injecting thermosetting polymers or thermoplastic onto the mold cavity, which in turn will be solidified into finished parts before they are ejected out of the mold.
Prototype injection molding is built quite quickly; the machined parts/product posses the functionality and the shape of a plastic prototype that can be tested for function fit and form. The mold can be warrantied for up to 10,000 cycles, while the production molds come with a lifetime warranty.
A manufacturing trend that has been making waves is the use of 3D printed parts for prototypes, test then jumping into the production of molds. Even though the process is quite fast, it will produce underwhelming results due to some limitations that come with 3D printing, like limited availability of plastic materials in comparison with injection molding.
The process of Prototype injection molding
At APT-Mold, we have simplified and shortened the process of quoting, making everything easier for you as a client.
- Loading of the 3D CAD file (STP or step format) enabling us to get instant mold or quote
- Upon confirmation of the order, as APT-Mold we will start the mold and part order procedure
- Our engineers will review the tooling designs
- After design approval, the building of injection mold commences
- The client will examine the prototype samples for approvals
- The part production begins.
Types of injection molding
Plastic injection molding
It’s a production process whereby the thermoplastic resin pellets are injected onto a heated barrel. The resultant molten material is shot into the mold cavity, cooling of the material begins. Once the desired cooling rate id reached, the solid production-grade parts are ejected with a wide variety of pins as A-side and B-side of the mold separate.
Liquid Silicone Rubber Molding
This is usually a thermoset process that blends two-components of a compound together, which is, in turn, heat-cured using a platinum catalyst producing the final LSR part.
In comparison to thermoplastics, LSR is a thermosetting polymer, which essentially means that the molded state is permanent. Once liquid silicone rubber molding is produced, it cannot be melted again.
The LSR part has a brilliant chemical, electrical, thermal resistance properties.
Over molding& Insert Molding
Insert, and over-molding is an injection molding manufacturing process that produces a single multi-material component. In much simpler terms, over-molding is when substrate parts are molded over a second material.
As for insert molding is when a pre-formed part is specially designed to fit onto another injection molded part.
At APT-Mold, our injection molding machines ranging from 7-500 tons can produce high-quality engineering-grade injection molded parts at fast and affordable rates that will significantly reduce time to market frame.
Our wide variety of press services will enable us to meet your prototype injection molding needs and preferences ranging from10 to 100,000+ parts.