Plastic Injection Molding 101

A back to basics and refresher eBook on plastic injection molding

made with
Table of Contents
1. Plastic Injection Molding 101: The Injection Press

2. Plastic Injection Molding 101: Choosing the Best Resin

Material

3. Plastic Injection Molding 101: Cold Runner vs. Hot

Runner Molds

4. Plastic Injection Molding 101: Costs of Manufacturing

a Mold

5. Plastic Injection Molding 101: Common Terminology

6. Plastic Injection Molding 101: Types of Plastic Molding

7. Let's Chat
Plastic Injection Molding
101: The Injection Press
Our website is frequently visited by product designers, engineers and
purchasing agents who are looking for information on plastic injection
molding. With this in mind, we created this basics 101 eBook to give our
readers a better understanding of the presses, processes and pitfalls in
our industry.

We begin this eBook with information on the basics of plastic injection

molding presses. We hope you find this information useful. If you have
specific questions, please do not hesitate to contact us.

Injection press basics

While plastic injection molders will help you determine the size of the
machine needed to get the best result, a project designer or engineer can
get a good estimate based on some basic information. By knowing
approximately what size machine will be required, you can better source a
plastic injection molder that will meet your needs.

Let's take a look at how plastic injection molding presses are rated
or classified:

Often plastic injection companies will provide a molding equipment list on

their website. It may look something like this:

3- 68 Ton Injection Molding Presses

5- 123 Ton Injection Molding Presses

5- 154 Ton Injection Molding Presses

5- 202 Ton Injection Molding Presses

5- 233 Ton Injection Molding Presses

4- 400 Ton Injection Molding Presses

So, what does this mean?

Plastic injection molding presses are classified or rated based on tonnage,

or more accurately the clamping pressure or force. Presses can run in
size from less than 5 tons of clamping pressure to over 4000. The higher
the press ton rating, the larger the machine.

A machine rated for 68 tons can deliver 68 tons of clamping pressure.

This pressure keeps the mold closed during the injection process. Too
much or too little pressure can cause quality issues. Too much or too little
pressure can also cause flashing, where the excess material appears on
the part edge. Pressure also impacts the viscosity of the plastic being
used in the project. Melt Flow Index or MFI is a measure of the ease of
flow of the melt of a thermoplastic polymer. Plastic compounds react
differently to pressure based on their MFI. The higher the MFI, the higher
the pressure needed.
Second, let’s figure out how much clamping force or pressure is
required

Many factors are taken into consideration when determining the size of the
press. The size of the part, the polymer being used and something called
the safety factor. The safety factor is an additional numerical percentage
buffer that is added to the calculation to help avoid defects in the final part.
Some recommend adding 10% to allow for the safety factor. As
mentioned earlier, the MFI (Melt Flow Index) of the plastic compound will
also impact the pressure needed to produce the part. Many calculations
include the platen size as well as the mold and part size, however, to get
an estimate of the press size your project will need, we have simplified it
even further.

Many plastic injection professionals use a general rule of thumb of 2.5

times the surface square inches of the part to be produced. So, if you
have a part with 42 square inches than you would need a press size with
105 tons of pressure. If you add 10% for a safety factor, you will need to
use a press with a minimum of 115 tons of clamping force. A press size of
120 tons would be able to accommodate your plastic injection molded
product.

Lastly, let’s look at how you can identify a plastic injection molder
that is right for your project

Once you have an estimate of the press size, you will need, you can
identify plastic injection molding companies that will meet your
requirements. In general, molders with a greater number and wider
selection of press sizes will be able to accommodate the needs of your
project. If you are not working with a completed mold, look for a plastic
injection company who can design and build the mold. They will have a
better understanding of how to maximize the manufacturing process and
will often offer tooling allowances. This, in turn, will minimize the overall
cost of your project.

In the end, your plastic injection molder will determine which machine
would be best suited for your project. Larger presses can accommodate
larger molds and multi-cavity molds often reducing the cost per part.
However, larger molds are more expensive. Choosing the right press size
can balance the upfront tooling expenditures with long-term manufacturing
costs.
Plastic Injection Molding
101: Choosing the Best
Resin Material
The number of polymer compounds has grown over the past 20 years. As
a result, plastics are being used in more applications than ever before.
These materials are gaining a reputation for strength and endurance.
Combine these improvements with the advantages of corrosion resistance
and aesthetic appeal and plastics are taking center stage in the
manufacturing of many consumer and industrial components. Due to their
versatility, strength and light weight characteristics, plastics are also taking
a larger role in the transportation, medical and construction industries.

Here are five requirements to keep in mind when choosing your

resin:

The final part appearance including surface texture and transparency or

color requirements
The part strength, flexibility or rigidity
The chemical or environmental (the wind, rain, cold or heat) resistance
Regulatory requirements that need to be met including FDA, RoHS,
REACH and NSF
The life expectancy of the part

A plastics primer – thermoset vs. thermoplastic

Plastics fall into two basic categories, thermoset plastics, and
thermoplastics. To help you remember the difference, think of thermosets
just as the term implies, they are “set” during processing. When these
plastics are heated, it creates a chemical reaction that “sets” the part into
a permanent form. The chemical reaction is not reversible, so parts made
with thermosets can’t be re-melted or reshaped. These materials can be a
recycling challenge unless a bio-based polymer is used.

Thermoplastics are heated then cooled in a mold to form a part. Once the
parts are cooled, they revert to their original state and can be re-melted
and cooled again. For this reason, thermoplastics are easier to reuse and
recycle. They comprise the majority of the manufactured polymer resins
on the market today and are used in the injection molding process.

Fine tuning the resin selection

Thermoplastics are categorized by family and type. They fall into three
main categories or families; commodity resins, engineering resins, and
specialty or high-performance resins. The high-performance resins also
come with a higher cost. That is why commodity plastic resins are often
used for many everyday applications. Commodity resins are easy to
process and are inexpensive. They are often found in standard mass
produced items like packaging. Engineering resins are more expensive
but offer better strength and resistance to chemicals and environmental
exposure.
Within each of these families, some resins have different morphology.
Morphology describes the arrangement of molecules in a resin and fall
into two categories, amorphous and semi-crystalline. Amorphous resins
have the following characteristics: they shrink less when cooled, offer
better transparency, work well for tight-tolerance applications, tend to be
brittle and lack chemical resistance. Semi-crystalline resins have the
following characteristics: tend to be opaque, offer excellent abrasion and
chemical resistance, are less brittle and have higher shrinkage rates.

Examples of available resins

Amorphous

Download a PDF of the resin chart above here

An example of an amorphous, commodity resin is polystyrene or PS. Like
most amorphous resins, it is transparent and brittle, but it can be used in
high-precision applications. It is one of the most widely used resins and
can be found in plastic cutlery, foam cups, and plates.

Higher up on the amorphous scale are the engineering resins such as

polycarbonate or PC. It is temperature and flame resistant and has
electrical insulating properties, so it is often used in electronic
components.

An example of a specialty or high-performance amorphous resin is

polyetherimide or (PEI). Like most amorphous resins, it offers strength
and heat resistance. However, unlike most other amorphous materials it is
also chemically resistant, thus often found in the aerospace industry.

Semi-crystalline

An inexpensive semi-crystalline commodity resin is polypropylene or PP.

As with most semi-crystalline polymers, it is flexible and chemically
resistant. The low cost makes this resin the choice for many applications
such as bottles and packaging.

A popular engineering, semi-crystalline resin is polyamide (PA or Nylon).

PA offers chemical and abrasion resistance as well as low shrinkage and
warp. There are bio-based versions available making this material an
earth-friendly alternative. The toughness of the material makes it a light-
weight alternative to metal in automotive applications.

PEEK or polyetheretherketone is one of the most widely used semi-

crystalline high-performance resins. This resin offers strength as well as
heat and chemical resistance and is often used in demanding
environments including bearings, pumps, and medical implants.

Finding the right resin

When selecting a plastic resin, you should begin by choosing the family of
material that will give you most of the properties you want. Once
determined, you can select the appropriate grade of material. There are
several online databases that can assist with providing a benchmark from
which to work. UL Prospector (formerly IDES) is probably one of the most
well-known databases for material selection. MAT Web also has an
extensive database and The British Plastics Federation provides high-
level data and descriptions.

Plastic additives to improve characteristics

Various resins have particular properties for which they are known. As we
have seen, resin families (commodity, engineering, and high-
performance/specialty) contain both amorphous and semi-crystalline
alternatives. However, the higher the performance, the higher the cost. To
help keep costs low, many manufacturers use additives or fillers to obtain
the qualities they need at a lower cost. These additives can be used to
improve performance or convey other characteristics to the final product.

Below are some of the most common additive applications:

Antimicrobial – Additives used in food-related applications or high-contact

consumer products.

Antistatics – Additives used to decrease the static electricity conduction

and are often used in sensitive electronics.

Plasticizers and fibers – Plasticizers make a resin more pliable, whereas

fibers add strength and stiffness.

Flame retardants – Additives used to make products resistant to

combustion.

Optical brighteners – Additives used to improve whiteness

Colorants - Additives that add color or special effects such as

fluorescence or pearlescence.

The final selection

Choosing the right material for a project is one of the most important
factors in creating perfect plastic parts. The advances in polymer science
have contributed to the development of a large selection of resins from
which to choose. It is important to work with an injection molder that has
experience with a variety of resins and applications including resins that
are compliant with FDA, RoHS, REACH and NSF.

Over the years, The Rodon Group has developed strategic relationships
with the best resin suppliers in the country. We have over 50 years of
experience using certified commodity and engineering resins that adhere
to our stringent manufacturing standards. Unless you are well-versed in
resin selection, you should always consult with your injection molder to
determine the best material for a particular project.

Learn more about the other key factors in manufacturing a perfect plastic
part in our eBook

Sources: American Chemistry Council; Georgia Institute of Technology,

Atlanta, GA; RTP Engineering Plastics; Blackwell Plastics; British Plastics
Federation; Hardie Polymers; Wikipedia.
Plastic Injection Molding
101: Cold Runner vs. Hot
Runner Molds
Every plastic part starts in a mold. Injection molds are classified into two
main types, cold runner and hot runner. Each has its advantages and
disadvantages. Your plastic injection molder will be able to give you the
costs and benefits of using these different systems. However, by
understanding the key differences of these technologies, you can have a
more educated discussion on the type of mold that would best fit your
project.

The cold runner mold

Cold runner molds usually consist of 2 or 3 plates that are held within the
mold base. The plastic is injected into the mold via the sprue and fills the
runners which lead to the parts in the cavity. In 2 plate molds, the runner
system and parts are attached, and an ejection system is used to
separate the pair from the mold. For those of you who assembled a model
car at some point in your youth, the runners and the parts were not
separated. The child assembling the model was responsible for that final
part of the process. In 3 plate molds, the runner is contained on a
separate plate, leaving the parts to be ejected alone. In both systems, the
runner is re-cycled and reground, reducing plastic waste. However, these
processes can increase cycle time.

The hot runner mold

Hot runner molds consist of 2 plates that are heated with a manifold
system. The manifold sends the melted plastic to nozzles which fill the
part cavities. There are several types of hot runner systems, however, in
general, they fall into two main categories; externally heated and internally
heated. The externally heated systems are well suited to polymers that
are sensitive to thermal variations. Internally heated systems offer better
flow control. The hot runner process eliminates runners entirely, so
recycling and regrind (which can only be done with virgin plastics) do not
impact cycle times. A variation of this system is called an insulated
runner. The insulation, rather than heat, keeps the plastic in a molten
state. This system can only accommodate a few types of plastics,
specifically semi-crystalline polymers which have a low thermal
conductivity.

Advantages and disadvantages of each system

Cold Runner Systems

Advantages:
-Comparatively cheaper to produce and maintain

-Accommodate a wide variety of polymers, both commodity and

engineered

-Color changes can be made quickly

-Fast cycle times if the systems include robotic assist in removing runners

Disadvantages:

-Cycle times are slower than hot runner systems

-Plastic waste from runners (particularly if they cannot be reground and

recycled)

Hot runner systems

Advantages:

-Potential faster cycle times

-Eliminates runners and potential waste

-No need for robotics to remove runners

-Can accommodate larger parts

Disadvantages:

-More expensive molds to produce

-Color cannot by easily changes

-Higher maintenance costs and potential downtime

-May not be suited to certain thermally sensitive materials

Professionals in the field of plastic injection molding should be your

primary resource for determining the best injection molding system for
your project. Look for injection molders who are familiar with all types of
plastics processing.
Plastic Injection Molding
101: Costs of
Manufacturing a Mold
A common question for designers and engineers is “How much will a
plastic injection mold cost?” It makes sense. Injection molds represent the
greatest expense in upfront production costs. And, there are many factors
that go into determining the cost. With any custom injection molding
project, your injection molder will be able to give you the final price tag.

Here we will review the variables that can impact the cost so that you can
be better informed in making a mold purchasing decision.

First, let us talk about the merits of having a mold built in the United
States.

The Rodon Group has been in this business long enough to have worked
with, or attempted to work with, molds that were created in Asia (more
specifically, China). Many of these molds are not built to meet strict
tolerances because they don’t have to be. As labor costs rise in China,
this no longer becomes an affordable manufacturing process. In addition,
molds made in other countries are made from lesser quality steel. Again,
this causes quality issues and shortens the life of the mold. Most high-
production molders in this country use only the best steel available for the
mold base and cavities. They utilize the latest technology in CNC
machining and have seasoned tool makers who know how to create
molds that meet the highest performance standards. We highly suggest
you consider using a U.S. manufacturer for you molding needs.
Not all quotes are created equal
Procurement and purchasing managers have the unenviable task of
obtaining quotes from a few mold makers for each project. Depending on
the input (in terms of drawings, prototypes or sample parts), the cost
quotes can vary greatly. Designers should look at all of these inputs and
determine the best molding solution. They may re-design the part to
maximize manufacturing efficiency and increase the number of parts that
can be made with each molding cycle. Generally, molds made with tighter
tolerances, more cavities and longer production life will take longer to
build and will cost more upfront. The savings with a high-quality mold are
long-term. These molds require less maintenance and last longer than
lower quality molds.

Following are some of the variables that impact the cost of a plastic
injection mold:

The core metal

For shorter production runs, some mold makers will use molds made from
aluminum. This is a perfectly reasonable choice if you will not need the
mold to perform long-term. However, if a project requires that a mold lasts
for several years, an aluminum mold may cost more in the long-run. In this
case, stainless steel is the best choice.

The number of cavities

It is pretty intuitive when you think about it. Fewer cavities in a mold
require less tooling work and time and ultimately less cost. A reputable
experienced molder will be able to maximize cavitation in the mold to
maintain the highest level of productivity. In general, most molders
recommend creating one mold per part versus creating a family mold.
Family molds are created with various cavities for assorted parts. They
tend to produce inferior products and have more downtime due to
maintenance issues.

Mold base
Think of the mold base as a case that holds all of the mold cavities,
inserts and components together. The cost of the base is estimated based
on the size of the mold and the type of steel used to make the base as
well as the customization required. Most mold bases come in standard
sizes and are further machined to meet the requirements of a specific
project.
Core/cavity machining
All molds must also be customized. Customization includes the placement
of cores, cavities, ejectors, cooling lines, etc. The steel used in the tool
also impacts cost. Hardened steel molds lasts the longest and are more
expensive to machine. Once done, however, they have a long production
life.

Part complexity
Just as the number of cavities plays a role in determining the cost of the
mold, so does part complexity. This includes the surface finish of the final
part as well as the number of undercuts required. Parts, which demand
tight tolerances, also contribute to the mold complexity.

Turnkey or vertically integrated injection molders

Some mold builders also manufacture the parts. This type of integration
can help defray the mold building cost. Often full service molding
manufacturers will subsidize a portion or all of the cost of the mold based
on the full term and value of the manufacturing contract. They will
amortize the cost of the mold so they can maintain profit margins while
providing the lowest possible per piece cost to their clients.
In summary, the cost of a quality injection mold is a major expense.
However, tight-tolerance, precision molds that are made from the best
steel available should last for years to come. The upfront cost must be
calculated or amortized into the lifetime value of the project. Will these
parts be in production for several years or several months? Does the
project require a high-volume of parts? Are faster cycle times required? If
you answered yes to these questions, then the initial investment in a
quality mold will lower the per part cost and will end up saving money in
the long-run.

We hope this overview of key cost factors helps you in getting and
comparing quotes for your future projects. Working with a reputable on-
shore molder, with a long-history of mold building for various industries, is
a great place to start your bidding process. If you are looking for high
volume, custom precision parts and innovative solutions, we hope you
keep The Rodon Group in mind.
Plastic Injection Molding
101: Common
Terminology
Plastic injection molding may not be rocket science, but it comes
pretty close. There are hundreds of terms used in the industry. We
have chosen to highlight the most common nomenclature used
when discussing mold parts, materials and problems.

Additives – These compounds are added to resins to improve the overall

performance and appearance of finished products. A key trend in this area
today is using additives that are made from organic materials such as
eggshells, wood pulp, rice hulls or materials that improve the
biodegradability of the plastic.

Alloy – A plastic alloy is a physical modification of an existing plastic to

achieve higher performance and or functionality. These alloys are often
used in the automobile industry and to replace metal parts.

Annealing - Annealing is the heating and slow cooling of a plastic part

which allows the polymer chains to recoil and relieve internal stresses.

Assembly – A secondary manufacturing function of joining finished parts

together.

Backing plate – A plate, which supports the mold, pins and bushings in
the injection machine.

Blister – As the name says, this is a part defect which appears as a small
bubble or blister on the surface of a part and it generally created by gas or
air bubbles.

Blow molding – The process follows the basic steps found in glass
blowing. A parison (heated plastic mass, generally a tube) is inflated by
air. The air pushes the plastic against the mold cavity to form the desired
shape. Once cooled, the plastic is ejected. This method is used to make
plastic bottles.

Bridge tool – An injection mold that makes parts until the final tool is
completed. These molds or tools are not meant to be production tools.

Bubbles – Similar to blisters, gas pockets, or voids that have formed

inside the plastic.

Cavity - The machined shape within a mold which created the form of the
plastic part.

Clamp – The mechanism that holds the mold in location during the
molding process.

Cold slug – A defect characterized by a small non-uniform area on the

part caused by an improperly heated piece of plastic becoming attached
to the part.

Colorant – A pigment system, usually in pelletized form, powder or liquid,

which is mixed with resin to produce the desired color.

Compression molding - The name of this molding method says

everything. A heated plastic material is placed in a heated mold and is
then compressed into shape. The plastic can be in bulk but often comes in
sheets. The heating process, called curing, insures the final part will
maintain its integrity. This molding method is often used to make large
objects such as automobile components.

Copolymer - A polymer derived from more than one type of monomer.

Core - A protrusion or set of matching protrusions, which form the inner

surface of a plastic part. They are often considered they “male” side of the
part.
Crazing – A defect that causes small cracks often caused by over-
stressing the plastic material.

Creep – The “set” that a molded part takes under stress, and does not
return to its original shape. Also known as “memory”.

Cure – The process of allowing a plastic to harden or stabilize.

Cycle – The overall time it takes for the plastic injection process to
complete a finished part.

Degassing – Opening and closing of a mold to allow gas to escape.

Trapped gas and/or air can cause parts defects such as blistering and
bubbles.

Delamination - This defect appears as a flaky surface layer on the part

and is often caused by contamination or moisture in the resin pellets.

Density – Mass per unit volume of a substance.

Dimensional stability - Ability of a plastic part to retain the precise shape

in which it was molded.

Draft – The angle or degree of taper in a side wall to help facilitate

removal of the parts from the mold.

EDM or electric discharge machining - A manufacturing process used

to create molds, where the shape of the mold cavity is obtained by
removing metal material using electrical discharges.
Ejection pin – Metal rods in the mold which push the parts from the mold.

Ejector return pins – Pins that push the ejectors back into position once
the parts have been released.

Ejector rod – A bar that engages the ejector assembly and pins when the
mold opens.

Elasticity – The ability of a material to return to its original state when

stretched.

Elastomer – A rubber-like material, which is highly elastic.

Extrusion – The process of forming tubes or continuous shapes by

pushing melted material through a die aperture.

Fabricating – The process of manufacturing plastic products through

various molding and forming methods.

Family mold – A mold which contains cavities for various parts.

Fan gate – A gate with a wider width that helps reduce warping through
stress.

Fill – The packing of material into the mold

Filler – An inert additive that adds strength or hardness to a part.

Finish – The surface texture to a part.

Flash gate – An alternative to a fan gate, which conveys the melted

resins into a thinner gate section creating a linear melt flow into the cavity.

Flash or burrs – A thin lip or protrusion beyond the body of the part that
is generally caused by poor clamping force, improper mold design and/or
mold damage.

Flow marks - A wavy pattern or discoloration caused by a slow injection

speed which allows the material to cool too quickly.

Flow rate – The volume of material passing a fixed point per unit time.

Gate – The channel into which melted plastic flows into a mold.

Hardness – The resistance of a material to compression, indentation and

scratching.

Hot-runner mold – Hot runner molds consist of 2 plates that are heated
with a manifold system. The manifold sends the melted plastic to nozzles
which fill the part cavities.

Injection Blow molding - A blow molding process in which the parison to

be blown is formed by injection molding.

Injection molding – A manufacturing process in which melted plastic is

injected into a mold to form a part.
Insert – An object, such as a magnet or screw, which is inserted into the
molded part.

Jig – The apparatus which holds and guides the tool during the
manufacturing process.

Machine shot capacity – The maximum volume of resin which can be

injected in a single stroke.

Masterbatch – A solid or liquid additive for plastic used for coloring

plastics or imparting other properties to plastics.

Memory – The action of plastic returning to its previous size and form.

Mold – A hollow form that plastic is injected or inserted into to

manufacture a plastic part.
Mold release – A surface preparation used to aid in the ejection of the
part from the mold.

Multi-shot molding – A process where two or more plastic substances

are injected into the mold to form a part. Toothbrushes are often
manufactured using this technique.

Nozzle - The hollow-cored metal nose screwed into the injection end of
the barrel which forms a seal under pressure. .

Orange peel – A patchy rough surface defect caused by moisture in the

mold cavity, or by incomplete pack-out.

Over molding – A two-shot process, in which two plastic substances, are

injected into a mold sequentially, usually a harder base material with a
coating of softer material.

Parting line – A line on a part formed when the two sides of the mold
come together.

Pinpoint gate – A very small gate, used in hot runner molds, to control
the flow of material.

Plastic – A polymeric substance of large molecular weight.

Plasticity - The quality of being easily shaped or molded.

Platens – Steel plates in the molding machine onto which the mold is
fastened.

Polymer - A substance that has a molecular structure consisting chiefly or

entirely of a large number of similar units bonded together, e.g., many
synthetic organic materials used as plastics and resins.

Prototype tool – Also called a soft tool, a preliminary mold built to

produce prototype parts and used to make adjustments to the final
production tool.

Purging – The process of cleaning the injection machine of remnant color

or materials prior to running a new part.
Ram – A plunger-like part which pushes the melted material into the mold.

Release agent – A compound, which is sprayed on the mold, or as an

additive, molded into the part to help facilitate the release of the part.

Retainer plate – A plate onto which the removable parts of the mold are
mounted.

Runner system – The channel system that allows the flow of the melted
material to fill the part cavities.

Short shot – A defect where the material does not fully fill the part cavity.

Shot – A complete cycle of the injection machine.

Shrinkage – The amount of volume reduction that takes place when a

plastic material cools.

Sprue – The opening feed that conveys material from the nozzle to runner
system in the mold.

Thermoplastic - A material that can be heated and cooled repeatedly

without changing the material structure. Highly recyclable.

Thermoset – A material, which when heated, is pressed or molded into a

shape. The heating process changes the structure of these materials, and
for this reason they cannot by re-heated.

Tie bars - Bars which provide structural support to the mold in the press.
The spacing between the tie bars dictates the size of the mold that can be
placed into the injection machine. The mold opens and closes riding on
the tie bars.

Toggle – A mechanism that is used to mechanically close the mold, as

opposed to hydraulic clamping.

Tool – The mold used to form plastic parts in an injection machine.

Undercut – Can be a design flaw that results in an indentation or

protrusion that inhibits the ejection of the part from the mold. Other times
undercuts are designed into a mold to ensure a part holds onto the correct
side of the mold.

Vent – A channel from the mold cavity that allows gas and air to escape
as resin is being injected into the cavity to prevent many types of defects
from occurring.

Weld line - Also called a knit line, the juncture where two flow fronts meet
and are unable to join together during the molding process. These lines
usually occur around holes or obstructions and cause localized weak
areas in the molded part.
Plastic Injection Molding
101: Types of Plastic
Molding
In today’s manufacturing environment, plastics are being used to make
everything from automotive body parts to human body parts. Each
application requires a special manufacturing process that can mold the
part based on specifications. This article provides a brief overview of the
different types of molding and their advantages and applications.

Blow Molding – Well suited for hollow objects, like bottles

The process follows the basic steps found in glass blowing. A parison
(heated plastic mass, generally a tube) is inflated by air. The air pushes
the plastic against the mold to form the desired shape. Once cooled, the
plastic is ejected.

The blow molding process is designed to manufacture high volume, one-

piece hollow objects. If you need to make lots of bottles, this is the
process for you. Blow molding creates very uniform, thin walled
containers. And, it can do so very economically.

Compression Molding – Well suited for larger objects like auto parts.

The name of this molding method says everything. A heated plastic

material is placed in a heated mold and is then compressed into shape.
The plastic can be in bulk but often comes in sheets. The heating process,
called curing, insures the final part will maintain its integrity. As with other
molding methods, once the part has been shaped, it is then removed from
the mold. If sheeting plastic material is used, the material is first trimmed
in the mold before the part is removed.

This method of molding is very suitable to high-strength compounds like

thermosetting resins as well as fiberglass and reinforced plastics. The
superior strength properties of the materials used in compression molding
make it an invaluable process for the automotive industry.

Extrusion Molding – Well suited for long hollow formed applications

like tubing, pipes and straws.

While other forms of molding uses extrusion to get the plastic resins into a
mold, this process extrudes the melted plastic directly into a die. The die
shape, not a mold, determines the shape of the final product. The
extruded “tubing” is cooled and can be cut or rolled for shipment.

Injection molding - Well suited for high-quality, high-volume part

manufacturing.

Injection molding is by far the most versatile of all injection molding

techniques. The presses used in this process vary in size and are rated
based on pressure or tonnage. Larger machines can injection mold car
parts. Smaller machines can produce very precise plastic parts for
surgical applications. In addition, there are many types of plastic resins
and additives that can be used in the injection molding process,
increasing its flexibility for designers and engineers.

The process itself is fairly straightforward; however, there are many

enhancements and customization techniques that can be used to produce
the desired finish and structure. Injection molds, which are usually made
from steel, contain cavities that will form the parts. Melted plastic is
injected into the mold, filling the cavities. The mold is cooled, and the parts
are ejected by pins. This process is similar to a jello mold which is filled
then cooled to create the final product.

The mold making costs in this method are relatively high; however, the
cost per part is very economical. Low part cost along with resin and finish
options have all contributed to injection molding’s popularity in today’s
manufacturing landscape.

Rotational Molding (Rotomolding)– Well suited for large, hollow, one-

piece parts.

This process uses high temperatures and rotational movement to coat the
inside of the mold and form the part. The constant rotation of the mold
creates centrifugal force forming even-walled products. Because it is
ideally suited to large hollow containers, such as tanks, it is not a fast
moving process. However, it is a very economical process for particular
applications and can be cheaper than other types of molding. Very little
material is wasted using this process, and excess material can often be
re-used, making it an economical and environmentally viable
manufacturing process.

Conclusion

Each type of molding has its strengths and weaknesses. Designers and
engineers need to understand these differences and the production
options available. There are always several approaches to a final
manufacturing solution. The molding company who consults on a specific
project should be able to provide additional insights into the applications
and materials that are best suited to an individual project.

For more insight into selecting a plastic injection molding company, please
review our “15 Questions to ask When Choosing an Injection Molder.” We
think you will find it a useful guide.
 Let's Chat
The Rodon Group is a
high volume plastic
injection molding
company that is proud
to produce quality
American made parts.

Learn more about us at

www.rodongroup.com

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