Oem Injection Moulding
Why Choose Us?
Engineering & Quality Control
Our robust engineering department, advanced quality management systems, team of highly trained professionals, and more than 13 years of machining experience ensure your job will get done right. Our quality-minded professionals are trained in all aspects of quality and written procedures, in order to assure that all our customer's specifications and requirements are met every step of the way.
Wide Product Range
We provide rapid prototyping and low volume production orders to customers in a variety of industries: Aerospace, automotive, defense, industrial machinery, agricultural machinery, construction machinery, transportation equipment, medical equipment accessories, and more.
Reliable On-Time Delivery
We use sophisticated job scheduling software and job tracking systems to monitor the progress of every job in production on a daily basis. These key factors have allowed us to provide our customers with consistently reliable on-time delivery.
Superior Customer Communications
We keep our customers well informed throughout every stage of the production process, from initial quoting through final delivery. Quotes are submitted in a timely manner, orders are promptly acknowledged, and manufacturing processes are monitored on a daily basis to ensure on-time delivery.
What is Oem Injection Moulding?
OEM Injection Moulding refers to the manufacturing process of producing custom plastic parts and components for Original Equipment Manufacturers (OEMs). In this process, raw plastic material is melted and injected into a custom-designed mould to produce a specific shape or design. These parts are then used in various industries such as automotive, healthcare, electronics, consumer goods, and more. OEM Injection Moulding is known for its high accuracy, consistency, production speed, and cost-effectiveness.
Advantages of Oem Injection Moulding
High Efficiency- Fast Production
There are several good reasons that OEM injection molding is known as the most common and most efficient form of molding. The process itself is extremely fast compared to other methods, and the high production output rate makes it even more efficient and cost-effective. Speed depends on the complexity and size of the mold but only about 15-120 seconds pass between each cycle time.
Complex Part Design
OEM injection molding can handle extremely complex parts, and uniformity, as well as the ability to make millions of virtually identical parts. To optimize the effectiveness of high-volume injection molding and maximize the precision and quality of your parts, key design elements should be taken into account. The part design must be developed to maximize the efficiency inherent in high-volume molding. With the right design, parts can be made consistently and with quality. Without a good design, costly processing mistakes can be made.
Enhanced Strength
Strength is one of the key factors that need to be determined when designing a OEM injection molded part. The designer will need to know if the part needs to be flexible or rigid so that he/she can adjust the integrating ribs or gussets. Understanding how the customer will be using the part and what type of environment the part will be exposed to is also important.
Flexibility- Material and Color
Choosing the right material and color for a project are two of the essential factors in creating plastic parts. Due to the wide variety of both, the possibilities are almost endless. The advances in polymers over the years have contributed to the development of a large selection of resins from which to choose. To ensure you select the right resin for your project, keep in mind the following variables: impact strength, tensile strength, a flexural modulus of elasticity, heat deflection and water absorption.
Reduced Waste
When looking for a high-volume OEM injection molding partner, it's important to consider companies' green manufacturing initiatives, as these signify a commitment to quality, sustainability, and optimal safety. During the molding process, excess plastic is generated. You want to look for a company that has a system in place to recycle its excess plastic. The most eco-friendly plastic injection molding companies employ state-of-the-art machinery to assist them in minimizing waste, transportation, and packaging.
Low Labor Costs
Labor costs are typically relatively low in OEM injection molding, in comparison with other types of molding. The ability to produce the parts at a very high level with a high output rate helps with its cost efficiency and effectiveness. The molding equipment typically runs with a self-gating, automatic tool to keep operations streamlined and production ongoing, requiring minimal supervision.
Automotive
Many plastic parts in automobiles require a range of intricate design features to function correctly. Typical injected molded components used in automobiles include bumpers, dashboards, and smaller parts, such as cup holders, mirror housings, and many more.
Medical
The use of plastics has been widely used for medical device manufacturing. Offering superior quality and precision, custom plastic parts are used in a variety of medical components and offer exceptional mechanical properties.
Construction
Manufacturers use OEM injection molded parts to produce cost-effective construction parts and products, including tools, fasteners, and accessories.
Plumbing
There was a time when metal, ceramic, or concrete materials were predominantly used in industrial and residential plumbing. Today, while metal pipes, including copper and galvanized steel, are still commonly used, plastic plumbing components have been found to offer superior qualities and offer many valuable characteristics.
Appliance
Appliance manufacturing is another industry that favors the high-volume, highly repeatable process of creating plastic components for product production. Components such as gears, pulleys, pumps, shelves, and trays are a few examples of plastic parts incorporated into refrigerators, dishwashers, kitchen gadgets, and more, which offer greater durability and value.
Electronics
When you think of electronics, it's most likely you think of wires and metal. Although, corrosion-resistant plastic can help improve the performance of electronic components. When compared to other materials, plastics have a superior ability to improve safety and provide insulation. Your television, computer mouse, and many other devices often incorporate parts created with the OEM injection moulding process.
What Plastics Are Used in OEM Injection Moulding?
1. Acrylonitrile Butadiene Styrene (ABS)
This tough, impact-resistant plastic is widely used across industry. With good resistance to acids and bases, ABS also offers low shrinkage rates and high dimensional stability.
2. Polycarbonate (PC)
This strong, impact resistant plastic has low shrinkage and good dimensional stability. A transparent plastic that is available in different optically clear grades, PC can provide a high cosmetic finish and good heat resistance.
3. Aliphatic Polyamides (PPA)
There are many different types of PPA (or nylons), each of which has its own advantages. Generally-speaking, nylons offer high strength and temperature resistance as well as being chemically resistant, apart from against strong acids and bases. Some nylons are abrasion resistant and offer good hardness and stiffness with good impact strength.
4. Polyoxymethylene (POM)
Commonly known as acetal, this plastic has high hardness, stiffness, strength and toughness. It also has good lubricity and is resistant to hydrocarbons and organic solvents. Good elasticity and slipperiness also provide advantages for some applications.
5. Polymethyl Methacrylate (PMMA)
PMMA, also known as acrylic, provides good optical properties, high gloss and scratch resistance. It also offers low shrinkage and less sink for geometries with thin and think sections.
6. Polypropylene (PP)
This inexpensive resin material delivers high impact resistance in certain grades but can be brittle in cold temperatures (in the case of propylene homopolymer). Copolymers offer greater resistance to impact while PP is also wear-resistant, flexible and can provide very high elongation, as well as being resistant to acids and bases.
7. Polybutylene Terephthalate (PBT)
Good electrical properties makes PBT ideal for power components as well as automotive applications. The strength ranges from moderate to high depending on glass fill, with unfilled grades being tough and flexible. PBT also shows fuels, oils, fats and many solvents, and it also doesn't absorb flavours.
8. Polyphenylsulfone (PPSU)
A dimensionally stable material with high toughness, temperature and heat resistance, PPSU is also resistant to radiation sterilisation, alkalis and weak acids.
9. Polyether Ether Ketone (PEEK)
This high temperature, high-performance resin provides heat resistance and flame retardancy, excellent strength and dimensional stability, as well as good chemical resistance.
10. Polyetherimide (PEI)
PEI (or Ultem) offers high temperature resistance and flame retardancy, along with excellent strength, dimensional stability and chemical resistance.
OEM injection moulding parts materials refer to the types of plastic used in the moulding process. These materials are chosen based on their properties, such as strength, flexibility, resistance to heat and chemicals, and cost. The choice of material is critical as it directly influences the performance and durability of the final product.
The variety of plastic materials available for injection moulding is vast. From thermosetting plastics that solidify permanently once moulded to thermoplastics that can be remoulded and recycled, the options are many. Each material has its unique set of characteristics and is suitable for specific applications.
For instance, Polyethylene (PE) is known for its high durability and low cost, making it suitable for packaging, containers, and pipes. On the other hand, Polycarbonate (PC) is recognized for its high impact strength and transparency, making it ideal for applications like eyewear and medical devices.
The Importance of Choosing the Right Material for OEM Injection Moulding
The selection of the right material for OEM injection moulding is a critical step in the manufacturing process. The type of material chosen impacts not just the physical and chemical properties of the final product but also its aesthetic appeal, longevity, and the overall cost of production.
Different materials have different melting points. The choice of material will determine the temperature at which the plastic needs to be heated for moulding. This, in turn, affects the energy consumption and cost of the process.
Materials vary in terms of their strength, stiffness, flexibility, and resistance to heat, chemicals, and UV radiation. These characteristics play a significant role in determining the functionality and durability of the final product. For instance, a part that needs to withstand high temperatures or harsh chemicals will require a material with high heat and chemical resistance.
The choice of material also influences the aesthetics of the final product. Factors such as colour, transparency, and surface finish are all dependent on the type of plastic used.
Process of OEM Injection Molding
Preparatory to the injection of the material in the mold, both the halves of the mold are closed by a clamping unit. Each half of the mold is attached to the injection molding machine and the other half can slide. The powered clamping unit applies sufficient force to push the halves together hence keeping them securely packed while the material is injected. Larger machines take longer to clamp the mold though.
Plastic pellets are inserted into the OEM injection molding machine and moved towards the mold by the injection unit. The material is given enough heat and pressure to melt during this time. The molten plastic formed is then injected into the mold expeditiously and this amount of material that is injected is referred to as the 'shot.' The injection time can be determined by shot volume, injection pressure, and injection power.
In this step, the molten plastic that is inside the mold starts to cool down after it contacts the interior mold. Furthermore, as the plastic cools it solidifies into the shape of the desired part of which some part may shrink during cooling. The mold cannot be opened until the cooling time has passed. The cooling time depends on the thermodynamic properties of the plastic along with the wall thickness of the part.
The last stages include ejection from the machine which is done by an ejection system attached to the rear half of the mold. After the opening of the mold, the part is pushed out of the mold. However, a certain force is needed to eject the part because during cooling the part that shrinks ends up clinging onto the mold. To prevent that, a mold release agent is sprayed onto the surfaces of the mold concavity before the injection of the material in the clamping stage. Therefore, as soon as the part is ejected, the mold shuts down for the next shot to be injected.
OEM Injection Moulding Considerations
There are a number of considerations to bear in mind before undertaking OEM injection moulding:
Financial
The entry cost for injection moulding manufacture can be high – given the cost of the machinery and the moulds themselves.
Production Quantity
It is important to determine how many parts you wish to manufacture so as to decide whether injection moulding is the most cost-effective production method.
Design Factors
Minimising the number of parts and simplifying the geometry of your items will make injection moulding easier. In addition, the design of the mould tool is important to prevent defects during production.
Production Considerations
Minimising the cycle time will aid production as will using machines with hot runner moulds and well thought-out tooling. Such small changes and use of hot runner systems can equal production savings for your parts. There will also be cost savings from minimising assembly requirements, especially if you are producing many thousands of even millions of parts.
Common Quality Problems of OEM Injection Molding
Color Difference
The color of the injection molded part is different from the single standard color sample when viewed with the naked eye, and it is judged as color difference under a standard light source.
Insufficient Injection Molding (Lack of Glue)
The injection molded parts are not full, and there are bubbles, voids, shrinkage cavities, etc., which do not match the standard model, which is called lack of glue.
Warping Deformation
The shape of plastic parts rotates and twists after the plastic parts are demoulded or within a later period of time. If there are straight sides facing inward, or outward warping or flat parts have ups and downs, such as shift forks and reinforcing seats Equal deformation can be divided into local and global deformation.
Uneven Color (Mixed Color)
The color of the surface of the injection molded part is not uniform, there are shades and different hues, which is called mixed color.
Corrugation
The surface of the injection molded part has a spiral or cloud-shaped corrugated unevenness, or there is a corrugated pattern inside the transparent product, which is called corrugation.
Overflow Edge (Flash Edge, Front Edge)
Thin (flash edge) rubber material appears around the parting line around the injection molded part or on the sealing surface of the mold, which is called overflow edge.
Silver Lines
Very long, needle-like silver-white fine lines like frost on the surface of injection molded parts. The direction of opening is along the direction of material flow. Where the plastic parts are not completely filled, the front end of the fluid is rough, which is called silver. Silk pattern (silver pattern).
Weld Mark (Grain)
The linear mark on the surface of the plastic part is formed by the fusion of plastics in the mold, and the melts are not completely fused together at the intersection, and cannot be fused with each other to produce weld lines, mostly manifested as a straight line, developing from deep to shallow, this phenomenon has a certain impact on appearance and mechanical properties. Such as the weld line at the bottom of the hook plate.
Future Trends and Advancements in OEM Injection Molding Technology
OEM injection molding industry is constantly evolving, and new technologies are being developed to improve the quality, efficiency, and sustainability of component production. One of the most significant advancements in recent years has been the development of 3D printing technology. 3D printing can be used to create molds and dies for injection molding, offering more design flexibility and shorter lead times than traditional tooling methods.
Another trend in OEM injection molding is the use of advanced materials such as bioplastics and composites. Bioplastics are made from renewable resources such as cornstarch and sugarcane, making them a more sustainable alternative to traditional plastics. Composites, on the other hand, offer unique properties such as high strength-to-weight ratios, resistance to corrosion, and thermal stability that make them ideal for specific applications.
Automation is another area of ongoing research and development in OEM injection molding. Automation can help to increase production speed, reduce waste, and improve the consistency of component quality by minimizing human error. Robotics and artificial intelligence are two emerging technologies that may play a role in automating plastic injection molding processes in the future.
In addition to these advancements, there is also a growing interest in sustainable manufacturing practices. Manufacturers are increasingly looking for ways to reduce waste, conserve energy, and minimize the environmental impact of their operations. This has led to the development of new materials and techniques that use renewable resources or produce fewer emissions and waste products.
Factors to Consider When Selecting OEM Injection Moulding Materials
Selecting the right material for OEM injection moulding involves considering several factors. The intended use of the final product is, of course, a critical factor. The environmental conditions it will be exposed to, the level of stress it will endure, and the desired aesthetics are all important considerations.
Moreover, the material's properties, such as its strength, flexibility, heat and chemical resistance, and cost, need to be evaluated. The material's recyclability may also be a significant factor, especially in today's increasingly eco-conscious world.
Lastly, it's essential to consider the moulding process itself. Different materials have different melting points, flow rates, and cooling times. These factors can impact the efficiency and cost-effectiveness of the production process.
5 Factors that Affect OEM Injection Molding Quality
Design of the Mold
The intended plastic product. This part of the machine is usually made with high-grade alloys like steel or aluminum. It's important that all the parts and components of the mold tooling are in good condition to ensure that the injection molding process is smooth sailing.In OEM injection molding, the mold tooling component is responsible for defining the shape of
Thickness of the Product Walls
OEM injection molding is used in the manufacturing of a wide range of plastic products for every day and industrial use. Keeping this in mind, the thickness of a product's walls is also a crucial element in the success of injection molding.
Runner Presence
The molding component of an OEM injection molding machine is usually etched with runners that facilitate the flow of the molten plastic resin pellets into the mold. While you may encounter two different kinds of runners - hot runners and cold runners - an efficient injection molding process gets rid of this component altogether.
Surface Finishing
Aside from the dimensional quality of the molding component, its surface finishing also helps determine the quality of the ejected product. There exists a number of surface finishing types like matte, shiny, stone-like, semi-gloss, and others.
Raw Materials
Finally, the raw materials can also influence the quality of OEM injection molding. Materials like polystyrene, ABS, polycarbonate, and polypropylene are just some of the most common resins used for this manufacturing technique, but not all of these materials can be the best choice for every purpose.
The quality of a product manufactured using OEM injection moulding is heavily influenced by the material used. The choice of material dictates the product's physical and chemical properties, its durability, and its ability to meet the intended use's requirements.
A material's strength, for instance, will determine the product's ability to withstand physical stress. Its heat resistance will dictate whether it can endure high temperatures. Its chemical resistance will decide if it can resist degradation due to exposure to certain chemicals.
Furthermore, the material's aesthetic qualities, such as its colour and transparency, can significantly impact the product's appeal to consumers. Thus, choosing the right material is critical to ensuring the quality of the final product.
The company was founded in 2010. The company started from a small workshop with 5 CNC machines. After experiencing a difficult startup period, the business grows rapidly. Three years later, we moved to a larger plant and added 10 milling machines and 1 lathes. In 2015, Kevin decided to enter foreign market. With the rapid expansion of international business, the company moved again to a new location with 1500m2.
Ultimate FAQ Guide to Oem Injection Moulding
Q: What is injection molding factory?
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Q: What is the hardest plastic for injection molding?
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Q: Is extrusion cheaper than injection molding?
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