PLASTIC INJECTION MOLDING 101:

FROM DESIGN TO PRODUCTION

Table of Contents
What is plastic injection molding?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

What is the plastic injection molding process?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

What are the advantages of plastic injection molding? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

What are the types of plastic injection molding?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

What is a thermoplastic?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

What industries utilize plastic injection molding?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How is automation used in plastic injection molding?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

What are the steps of developing a plastic part?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

What are important considerations when selecting an injection molder? . . . . . . . . . . . . . . . . . . 13

Why choose PCI for your next plastic injection molding project?. . . . . . . . . . . . . . . . . . . . . . . . . 14

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 Plastic Injection Molding 101:
From Design to Production
What is plastic injection molding?
Plastic injection molding is the most commonly used
manufacturing process for the production of small,
medium, and large-sized plastic parts. The process
utilizes an injection molding machine, raw plastic
material, and a mold. The plastic is melted to molten
heat in the machine and then injected into the mold,
where it cools and solidifies into the final part.

Plastic parts are incorporated into products found in

almost every industry, including automotive, medical,
small engine, plumbing, industrial, agriculture, and
more. Using the latest plastic injection molding
technologies and production processes, manufacturers
can produce ultra-high qualities of plastic parts with the
highest level of precision and speed.

Like many manufacturing processes, plastic injection

molding has evolved greatly over the last 20 years.
Once driven by time and pressure, essential elements
of molding are now position, peak pressure, and
process repeatability. According to a feature in Plastics
Today, scientific molding expert John Bozzelli, and PCI
partner RJG, were major pioneers in the development
of decoupled and data-driven or “scientific molding.”
Plastic injection as an “art” gave way to plastics
processing as a science of repeatability, standardization,
and part success.

Make-up of an Injection Molding Machine:

An injection molding machine is made up of a material hopper, barrel, an injection ram/rotating screw, heating
device, moveable pattern, ejectors, and mold inside the mold cavity. Generally, machines work in a horizontal
manner.

The function of the clamping unit is opening and closing a die, and the ejection of parts. There are two types of
clamping methods - a toggle type shown and the straight-hydraulic type, which allows a mold to directly open
and close with a hydraulic cylinder.

The hopper is located at one end of the barrel, and the hydraulic rotating screw runs by electric motor. The
screw is rotated to melt plastic introduced from the hopper. After the required amount of molten plastic is
accumulated, the injection process is started. On the other side of the barrel, a mold is attached.

While molten plastic is flowing in the mold, the injection molding machine controls the speed of the screw (or
the injection speed). It also controls pressure as plastic fills the cavities. Speed control and pressure control is
set where screw position and injection pressure reaches a certain value.

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Make-up of an Injection Mold:
Molds for plastic injection consist of high-strength metal
components that have been machined to operate in two
halves. The molten plastic flows into a mold through a sprue
and fills cavities by way of runners and gates. Then, the mold
is opened after the cooling process and the ejector rod of
the injection molding machine pushes the ejector plate of
the mold to eject moldings.

The composition of an injection mold is significant in

order to function properly during the injection molding
process. Although molds typically have two halves, a
cavity side and a core side, there are often dozens of precision features that make up each half.

Almost all of the machined mold components that function to manufacture a custom-molded part are machined
to tolerances of less than +/- 0.001˝ or 0.025mm, one-third of the thickness of a piece of copy paper.

What is the plastic injection molding process?

The injection molding process cycle is quite short, usually lasting between six seconds and two minutes. The
process consists of the following stages:

Clamping: Prior to the injection of the heated plastic material into the mold, the
two halves of the mold must first be securely closed by the clamping unit. The
tremendous force of the clamping unit pushes the mold halves together and keeps
the mold securely closed while the material is injected. The time required to close
and clamp the mold is dependent upon the machine - larger machines with larger
openings require more time.

Injection: Raw plastic material, usually in the form of tiny pellets, is fed into the injection molding machine and
conveyed or augered towards the mold by the injection unit. The plastic material heats up by temperature and
compression as the screw conveys the plastic pellets through heated zones of the machine barrel. The amount
of melted plastic that is conveyed to the front of the screw is an exact portion that will become the final part after
injection. The amount of material that is injected is referred to as the shot, and once fully clamped, the machine
injects the material into the mold. Injection time can be estimated by the shot volume, injection pressure, and part
geometry.

Cooling: The molten plastic inside the mold cools as soon as it makes contact with
the interior mold surfaces. The cooling process solidifies the shape and rigidity of the
newly molded plastic part. It’s important to note that part shrinkage may occur during
the cooling process.

The mold can not be opened until the required cooling time has elapsed. The cooling
time requirements for every plastic molded part depend on the thermodynamic
properties of the plastic, wall thickness of the part, and the dimensional requirements for the finished part.

Ejection: Once the part has cooled inside the mold, it may be ejected
from the mold via the ejection system. Mechanical features of an injection
molding machine push the part out of the mold using the necessary force for
ejection. During this process, the machine has prepared a new shot of plastic,
and once the part is fully ejected, the mold is ready for the next part.

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What occurs during plastic injection molding post-processing?
Following the injection molding process, post-
processing applications are often required. This may
include secondary processes for decorative or functional
purposes. With injection molding, there are six common
types of injection molding post-processing applications.

• Gate Trimming • Pad Printing

• Painting • Heat Staking
• Laser Marking • Ultrasonic Welding

What are plastic injection molding machine

classifications?
Knowing the approximate size of the press size required to produce your
precision parts is essential in determining the best injection molding
partner based on the press capacity available. For example, larger presses
cannot accommodate smaller molds because they have far too much shot
capacity.

Injection molding machines are classified or rated based on tonnage, or

more specifically, 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 400 tons
can deliver 400 tons of clamping pressure. This pressure keeps the mold closed during the injection process,
and too much or too little pressure can cause quality issues.

Plastic Components, Inc. offers press sizes ranging from 35-ton up to 500-ton in Wisconsin and up to 1250-ton
in North Carolina.

Want to learn more about material

shrink rate calculation?
View PCI’s Material Shrink Rate Guide here.

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What are the advantages of plastic injection molding?
The aesthetic and functional versatility of plastic injection molding makes it an excellent choice to
manufacture a vast array of parts and products. Key advantages include:

Speed and cost-effectiveness Lightweight

Injection molding is a very simple process that can be Plastic is strong, yet it is considerably lighter than metal
highly automated, so it is very efficient. This reduces or other common parts materials. For this reason, many
production time, which may result in greater revenue as manufacturers consider metal to plastic conversion as a
well as cost savings. beneficial option for replacing metal or steel parts with
plastic parts.

Superior quality Design compatibility

Injection molding Injection molding
produces parts that are easily integrates with
precise and consistently computer-aided design
uniform. In fact, injection (CAD, computer-aided
molded parts have manufacturing (CAM),
very good dimensional and SolidWorks. So,
consistency compared while this process is
to other plastics manufacturing processes. There are also a good choice for
many data-driven producing uncomplicated
injection molding practices and resources that support items, it is equally valuable
the overall quality of a part. Examples include the use for producing highly complex or finely detailed parts,
of SolidWorks software for up-front design validation, as well as when precise specifications for a component
RJG eDart process controls, automation and robotics, need to be met.
and more.

Customizable colors Customizable product traits

Colorant providers are capable of producing a broad Over 15,000 variations of plastics are available on the
spectrum of colors to produce virtually any shade or market to achieve desired functional results. In addition,
visual effect. fillers such as glass fibers are added to increase strength,
or UV protection can be added to increase the durability
of products that will be exposed to the sun.

Compliance Sustainability
When needed, resins are available that comply with FDA, The process of injection molding produces minimal
NSF, REACH, and RoHS requirements. waste because it is so accurate and efficient, and any
excess material can often be recycled.

Is metal to plastic conversion a

process that could benefit your product?
Get our comprehensive guide here.

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What are the types of plastic injection
molding?
Plastic injection molding is not a one-size-fits-all process. Different techniques
can be used to achieve different types of end results.

Standard molding Insert molding

This basic technique uses a single color and material to Insert molding is an application in which a prefabricated
produce the part. It is commonly used to manufacture part is used as the substrate. This substrate may be made
everything from beverage containers and caps to auto of an alternative material to plastic (often it’s metal).
parts and toys.
Knobs and dials that have a plastic exterior over a metal
interior are examples of insert molding. The substrate
Two-shot (dual-shot) molding
is inserted into the mold, then plastic is injected onto
This is also a two-step injection molding technique, but it it. Typically this process uses thermoplastic resin as the
is done in one molding press and it allows you to create overmolding material.
a part or product using multiple colors and plastic types
simultaneously, without having to use a multi-stage Overmolding
assembly process. For instance, you might want to create
a power tool housing with a branded-color handle. This is a two-step process used to produce items that
require two different types of plastic -- for example, a
First, a substrate is injected by the primary press barrel. shaped handle with a soft outer material that makes it
Then, mold steel is exchanged and a second injection easier to grip.
unit molds the second shot. The bond between the
materials can be chemical or mechanical. First, the substrate part is produced; then each part is
individually moved to another mold where another
thermoplastic is molded over the substrate. The bond
between the two materials can be mechanical or chemical.

What is a thermoplastic?
Polymer resins become molten when heated, so they can be molded as desired
and then allowed to harden. The resulting plastic is called a thermoplastic.

There are several types of thermoplastic, each with distinct characteristics that
make it especially useful for certain applications and budgetary requirements.
Thermoplastics can be highly resistant to temperature extremes, and corrosive
materials or environments.

• Acrylic (PMMA) • Polyether ether ketone (PEEK)

• Acrylonitrile butadiene styrene (ABS) • Polyethylene (PE)
Common types
of thermoplastic • Polyamide (PA) • Polypropylene (PP)
materials include: • Polylactic acid (PLA) • Polyvinyl chloride (PVC)
• Polycarbonate (PC) • High Impact Polystyrene (HIPS)

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Let’s dive a little deeper into a few of the materials listed above…
Acrylonitrile Butadiene Styrene (ABS) combines the three monomers in its name to create a plastic that is
opaque, lightweight, and versatile. Molded using high temperature, it becomes shiny and heat-resistant; low-
temperature molding makes it strong and impact-resistant. ABS is used for drain pipe, small kitchen appliances,
auto parts, and LEGOs.

Polyamide (PA/nylon) is not only very strong but is also highly resistant to impacts, abrasion, and harsh
chemicals. It is commonly used for everything from auto parts and industrial components to medical devices,
clothing, shoes, and sports equipment.

Polycarbonate (PC) is transparent and extremely impact-resistant, so it is valuable for DVDs, eyeglass lenses,
coverings for cell phone faces, auto dashboard gauges, medical devices, and protective partitions.

Polyethylene (PE) is commonly used in both high density (HDPE) and low density (LDPE) variations for products
ranging from plastic bags and films to beverage containers.

High Impact Polystyrene (HIPS) is polystyrene to which rubber has been added to increase strength. It is an
inexpensive choice for applications that require rigidity and dimensional strength. There are optional variations
that meet FDA food-grade standards as well as high-gloss and flame-retardant options.

Polypropylene (PP) is extremely tough, resisting high heat, stress, impacts,

harsh chemicals, and water. It is food-safe so it’s used to make plastic
utensils, but it is also used for clothing, rugs, and car batteries.

Aligning with your injection molding partner to choose the best

resin early in the design for manufacturability process, is crucial to a
part’s production success. A good place to start is to have a general
understanding of the main types of resins.

What industries utilize plastic injection molding?

For OEMs in industries of all types, plastic parts are an
essential and economical option in product design and
production. In most circumstances, it makes sense to find
the lowest cost, lowest weight, and most durable material
to produce the product needed. Plastic injection molding is an
incredibly versatile manufacturing process that plays a critical
role in developing products from medical devices to automotive
components to appliances and more. In fact, plastics can reduce
the weight of parts by 50%, produce less scrap, and be formed
into more complex shapes and geometries. Let’s review some of
the top applications for injection molding and the valuable characteristics of plastic parts for each.

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. Common characteristics of plastic parts for the automotive industry include:

• Weather and wear-resistant • Certain polymers stable from • Lightweight for reduced
• High-heat plastic parts the degradation of chemical emissions/energy saving
maintain integrity in exposure • Noise and vibration reduction
high-temp scenarios • Effective alternative for • Reduced cost and weight
discontinued parts

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 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. Common characteristics of
plastic parts for the medical industry include:

• Variety of various colors, shapes, and sizes

• High level of design & application flexibility
• High tensile strength
• Resistant to high temperatures
• Reduced cost and weight

Construction: Manufacturers use injection molded parts to produce cost-effective construction parts and products,
including tools, fasteners, and accessories. Common characteristics of plastic parts for the construction industry include:

• Great stability and durability when exposed to • Energy efficient

environmental elements • Lightweight
• Cost-effective compared to metal or wood • Many finish options

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, including:

• Corrosion resistance
• Low heat conductivity
• Non-reactive to chemicals
• Reduced cost and weight

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. Common characteristics of plastic parts for the appliance industry include:

• Resistance to heat, chemicals, and corrosion • Design flexibility

• Added durability and longevity • Ability to incorporate complex processes, such
• Decreased weight as overmolding

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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 plastic injection molding process. Common characteristics of plastic parts for
the electronics industry include:

• Withstand high voltages and high temperatures • Superior insulating properties, dielectric
without degradation strength, and thermal performance
• Design flexibility • Reduced cost and weight

When creating a component for a product, the cost-

effectiveness and design flexibility of plastic injection
molding should always be taken into consideration.
Plastics can reduce the weight of parts by 50-percent,
can be formed into complex shapes, and produce
less scrap material (of which is typically recycled). The
industry examples listed above are just a few among an
extensive list of others that may benefit from injection
molded parts. Whenever repeatability, consistency,
affordability, and reliability are essential for a medium
to high volume thermoplastic component, injection

molding is an ideal solution.

How is automation used in plastic injection molding?

Just like many other industries, the
world of plastics is continuously
changing and growing. Companies
are continually investing in
automation to improve productivity
and increase capacity and
efficiency.

Plastic injection molding

processes are fast, efficient, and
precise when conducted by
experienced technicians utilizing
advanced automated machinery.
Automation helps ensure each
manufactured component will be
identical to the validated design.

Taking automation a step further, lights-out manufacturing describes processes, innovative machinery, and
technology that is put into place within facilities to conduct tasks that would normally need constant oversight
by on-site technicians. Essentially, an automated production facility can run “lights-out” – or without substantial
assistance from human labor, lights, heat, and other costly factors for a business. However, most highly automated
facilities still require the supervision of highly skilled laborers and technicians. Lights-out manufacturing processes
allow companies to keep facilities running 24 hours a day, seven days a week, with a scaled-back workforce or
virtual technician oversight.

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 Lights-Out Manufacturing
PCI’s Bunsen Drive facility ensures the maximum amount of
efficiency out of every square foot of space. Since the opening of
the Bunsen facility, the United States Government issued PCI a
patent to validate the processes that take place within the facility.
Every detail from the lighting to the part conveyance system has
been meticulously planned. This attention to the little nuances of a
manufacturing plant is what separates this facility from others in the
world. Additionally, infrastructure expansions have set the stage for
the additional production presses that have already been added, and more that will come in the future.

The advancements in automation and “lights-out” manufacturing processes have impacted the plastics
industry at a high level. It allowed businesses to improve in the areas of cost and turn-around time. It has also
allowed plastic part producers to lower the likelihood of defects and increase the overall quality of products created.

Five critical ways lights-out manufacturing has transformed injection molding include:
1. It has helped U.S. manufacturers gain a globally competitive
advantage.
2. It allows large orders to be completed quickly without the higher
costs associated with running additional shifts.
3. It provides a greater ability to meet quality control, delivery, and
cost containment requirements.
4. It requires a highly trained and dedicated workforce to manage
and maintain state-of-the-art automation equipment and
processes.
5. It creates an added level of protection for intellectual property.

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What are the steps of developing a plastic part?
Creating custom plastic parts does not need to be complicated and is now more accessible than ever. When you
align with a knowledgeable plastic injection molder, you will work together to develop a clear plan of action,
optimized design and will soon have the precision parts needed to get your product to market fast and on
budget. Below are the high-level steps in the plastic part development process.

1. Design for Manufacturing in Plastic

Injection Molding (Designing the Part)
One of the most important aspects of the
plastic part development process is taking the
necessary steps to avoid delays and reduce
the risk of costly design changes. Your injection
molder should have the necessary resources to
lead you through a comprehensive design for
manufacturability (DFM) process.

Did you know that manufacturers rank design as

the top factor in reducing overall manufacturing
costs? DFM involves designing a product that optimizes manufacturing efficiencies for the equipment and/or
process used in its production in order to realize the lowest possible unit costs at the highest possible quality. The
most important reason for integrating DFM into manufacturing a plastic injection molded product is that design
decisions can determine 70% of its manufacturing costs.

• Design for Manufacturing • Design for Assembly

• Design for Functionality • Design for Sustainability

While production checklists are still critical components of the process, the work that happens earlier in the
development cycle is what creates real efficiencies in regard to time and budget. When a tool-maker / injection
molder is involved early in the design and development cycle, customer objectives are understood and
unexpected surprises are avoided. It’s all about taking this 4-pronged approach:

Establishing a collaborative effort early on and working together to develop a true understanding of what it will
take to achieve the successful molding of a part, will create efficiencies for your part development process in a
number of ways.

2. Determine the Molding Process

There are different molding processes used in manufacturing plastics.
Custom injection molding is one of the most popular techniques used
to produce high-volume plastic parts using an open-and-close mold
function.

However, the process you choose will depend on different variables.

These include your initial design, the quantity of the parts needed, and
the overall use of the products. Additionally, working with an injection
molder that offers post-molding capabilities can help streamline your
process, create efficiencies, and reduce costs. Whether you’re looking
for post-molding services including hot stamping, inserting, heat staking,
or more, some injection molders are equipped to provide turn-key
solutions.

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 3. Prototyping
Working with a plastic prototype molding partner to create custom
injection mold tools and components built with a production mentality
will support the overall efficiency of your project.

Many OEMs consider prototype molds before going directly to the

manufacturing process for a lot of reasons. These are low-cost molds
that are typically different from production mold because they are meant
for short-term use only. In many ways, prototype molds are useful for
reviewing specifications, seeing how the part functions or behaves, and
overall validation of performance.

PCI ensures injection mold tools are built to specification, allowing

the customer to have full confidence that the prototype component is
capable of being tested, marketed, or even used for short-term or low-volume production needs. PCI values our
strategic partnership with plastic prototype development resources to provide our customers with:

• Single-cavity prototype tools which replicate the design characteristics of production caliber
tools (i.e. similar tools design process, material selection, gating, parting line configuration,
water line design, etc.)

• Collaboration with our plastic prototype development partners on business development

efforts, particularly for new programs, part development, and metal to plastic conversion
projects

• Fulfillment of the “project manager” role with respect to development work, third-party contracts
for prototype tooling, and low-volume molding

4. Plastic Part Manufacturing

In our section above on the injection molding process,
we walked you through the makeup of a mold, the basic
description of a molding machine, and the process cycle.
This cycle is short, using high-pressure injection of
material into the mold, where it is shaped. This is a process
implemented by the majority of injection molders. Factors
that will determine the best plastic part manufacturing
scenario for your unique component include:

• Adequate production space

• Molding machines size appropriate for your
unique part
• Scientific molding practices, data-driven
analysis, and automated processes
• A facility focused on the volume of parts that
best fits your needs
• Mold maintenance support
• Assembly capabilities
• Advanced metrology equipment to support
PPAP requirements

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What are important considerations when selecting
an injection molder?
Above, we talked about the best manufacturing
environment for your plastic part. But there are other
crucial attributes of an injection molder that should be
evaluated when selecting the best resource. When you
need thousands of parts produced on time and under
budget, how do you achieve peace of mind that you are
working with a true partner that will keep your needs in
mind? Here are a few considerations:

• Quality Standards: Do your parts need to pass • Available Resins: Material/resin selection is a critical
strict inspections or meet high safety and quality element to the design and production process for
standards? If so, it is imperative that you partner a successful product. Working with an experienced
with an injection molder that is ISO certified, which injection molder will help you ensure that the end-
guarantees that parts will be molded with correct use will be kept in mind throughout the design and
and specified materials. material selection process. In addition to the base
material that is determined to be the best option for
• Customer Service & Communication: your product, filler materials, and other additives can
Long-term business-to-business relationships require be included to enhance the properties of the part.
the extra element of exceptional customer service
and communication. Especially when working with • Value: Price is always a top factor for a manufacturer
complex parts or projects that include a high level when determining the best injection-molding partner.
of intellectual property sensitivity, working with an Budgets and ROI calculations are a part of doing
on-shore partner that is responsive to your needs business. However, consider the process of buying
is essential. a car. Sometimes a “bargain” deal may result in
costly repairs a few months later. Many elements
Particularly if your needs are specialized or unique, come into play when considering the overall price
finding a supplier that understands your industry, for part production, and more goes into a long-
materials, and challenges is crucial to the success of term relationship than just choosing the lowest
the project. quote. While the lowest-priced option may seem
like the best solution, it could cost you more money
in the long run.

Learn about PCI’s scientific molding practices

in our Complete Guide to Scientific Molding.

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 Why choose PCI for your next
plastic injection molding project?

PCI has been in business for over 32 years and has grown to include two manufacturing facilities and
a distribution center in Germantown, Wisconsin, one manufacturing facility in Cary, North Carolina
(Syracuse Plastics), and one manufacturing facility in Clearfield, Utah (SMI Molding). The team is made
up of passionate and dedicated employees who have built the finest operating system in the plastics
industry. Recipients of Plastics News’ Best Places to Work for seven years straight, the PCI team proudly
ship over 25,000,000 parts per month to customers worldwide.

PCI embraces the unique and specific needs of our customers. We are a partner that will work to
understands your industry, common materials, and unique challenges that are crucial to the success of
your plastic injection molded project.

How can we help with your next project,

tool transfer, or metal to plastic conversion?
Contact our knowledgeable team today!

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