Call us today on 01902 758282 or Email us at contact@fern-plastics.co.uk

WE SPECIALISE IN HIGHLY TECHNICAL PLASTIC INJECTION MOULDING UP TO 2.5KG IN ALL THERMOPLASTICS AND FINISHES

Fern Plastics’ custom plastic injection moulding process produces a bespoke plastic mould product to suit exact specifications and requirements. Plastic injection moulding is the process of melting plastic pellets, which are injected into a moulded cavity when malleable.
The malleable plastic fills the mould, solidifies and the final product is achieved. The process of injection moulding is fast, and creates an identical product with high precision, regardless of the complexity of the design.

Fern Plastics has an abundance of readily available engineering plastics for injection moulding, with over 200 tonnes of injection moulding polymers in stock. The varied range includes sustainable polymers and our recycled ABS is available in black and grey. In order to provide superior service, we supply over 200 grades and 150 colour shades in our main range of injection plastics, all with immediate availability.

injection

With an excellent reputation for efficient and effective project management, Fern Plastics offers reshoring opportunities for new customers to move the manufacturing of their plastic injection moulds to our facilities. Specialist engineers can also modify, maintain and repair your plastic injection tools in the in-house tool room. Having the capacity to handle large demand is thanks to a vast stock of injection plastics and 43 Arburg and Engel injection moulding machines that can mould parts of up to 2kg.

By utilising state-of-the-art injection moulding technologies, experienced engineers manufacture injection moulding products with great efficiency, close tolerances and en-masse. Fern Plastic’s prototypes and end production goods are produced with a quick turnaround, and thanks to continuous reinvestment, we offer cost-efficient tooling and unit costs, even for smaller
quantities.

ALL OUR INJECTION MOULDS BENEFIT FROM:

  • Modern Arburg and Engel injection moulding machines
  • Microprocessor controlled
  • 25 to 600 Tonne
  • Tiebar-less for flexibility
  • Pick and place robotics for consistent cycling
  • Improving productivity and quality
  • Insert moulding
  • Gas Injection moulding to improve aesthetics and reduce material content in thick sections
  • Process Control and SPC
  • 24 hours production on 3 shifts
  • Fully integrated production/management
    computer system
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OUR FEATURED PROJECTS

VALUE ADDED SERVICES

Fern Plastics’ speciality is plastic injection mouldings, but the service doesn’t stop there. We understand the need for a comprehensive service that will elevate your plastic moulds to the next level, which is why your unit costs include some value-added extras. From printing and laser marking, welding and drilling to plating, polishing and beyond, your plastic mouldings receive care and attention to take them to a superior quality while keeping unit rates competitive.

GAS-ASSISTED INJECTION MOULDING

This injection moulding technique improves aesthetics and reduces material content in thick sections. This variant of traditional plastic injection moulding uses pressurised nitrogen gas to maximise the resin flow inside the mould cavity. Gas-assisted injection moulding is an environmentally friendly option that is also cost-effective.

PLASTIC INSERT MOULDING

All injection moulds can be customised to include moulded-in fasteners, shafts, hubs, electrical contacts or connectors. The insert injection molding process involves moulding plastic around other non-plastic inserts. Insert moulding is used for simple projects as well as complex moulding. Insert injection molding is economical, efficient and offers a variety of options for design.

ULTRASONIC WELDING
Joining injection moulded parts by ultrasonic welding or heat welding is quick and efficient. The process of ultrasonic welding eliminates the need for screws, nails or bolts when joining complex parts. Pressure and ultrasonic frequencies are transmitted to the parts which are fused by vibration and heat. Ultrasonic welding is suitable for small complex parts and parts that need to maintain their aesthetic quality.

ASSEMBLY AND TEST

At Fern Plastics, plastic injection moulded parts are joined together using techniques like mechanical fastening, with springs or o-rings. An experienced team of engineers test moulded assemblies for pressure tightness to guarantee the quality of the end products.

SOPHISTICATED MOULD PRINTING
Pad printing, also known as tampo printing or tampography is the process of printing 2-dimensional images onto 3-dimensional shapes. This process gives you the freedom to print on complex substrates with uneven surfaces and shapes and produces high-quality detailed images. A silicone pad is used to transfer the images and up to 5 colours can be printed in one process using state-of-the-art tampo-printers.

LASER MARKING
Fern Plastics’ laser marking machine produces indelible marking or etching on plain, chromed or painted mouldings. We use precise layer removal to produce back-lit mouldings for medical uses or applications that require backlit electrical components. An efficient laser marking service offers detailed laser etching for serial numbers, barcodes and QR codes.

HIGH-QUALITY MOULD FINISHES
Fern Plastics can provide moulds with Chrome plating on highly polished ABS polymers or paint finishes applied to a broader range of substrates

JUST IN TIME LOGISTICS

Kanban and consignment stock systems are operated for all major customers. We have an excellent track record for having readily available stock and fast turnaround times.

INJECTION MOULD TOOLING

Fern Plastics offer project management from APQP to PPAP level 3 mould production and our in-house tool-room has both manufacturing and repair capabilities. We also provide customers with other toolmaking options thanks to a long-standing relationships with overseas manufacturers.

TOOLING & PROJECT MANAGEMENT

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Fern Plastics work cohesively to ensure the customer requirements are clearly understood and satisfied. Through working collaboratively from inception through to completion of the client’s plastic injection moulds, we consistently manufacture high-quality plastic moulds with accuracy, fast lead times and low unit costs. You will be assigned a project manager to overlook and coordinate your project from the outset.

Your project manager will come to understand the requirements, demands and uses of your plastic injection moulds. This information will then be conveyed to our design and production teams to ensure the most effective product is produced.

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  • Fully trained, qualified and experienced technical staff
  • DFMEA and APQP to full PPAP
  • CAD design with mould flow analysis to assist with product and mould tool design
  • Prototyping through partners in UK and Internationally
  • Fully-equipped in-house tool-room for manufacture, modification and repair of mould tools, jigs, fixtures and gauges
  • CAD-CAM for improved tool-making accuracy and reduced lead times
  • Long-standing reliable relationships with low cost economy toolmakers