Plastic Injection Moulding FAQs
We created a guide to answer your most common plastic injection moulding questions.
Plastic injection moulding works by heating thermoplastic polymers until they melt down after which they are injected into precise moulds at high pressure. When cooled, they form a solid shape. This process can be quickly repeated which makes it perfect for creating multiple parts with great accuracy in a short amount of time.
Learn more in our blog on what plastic injection moulding is used for.
Plastic injection moulding is an incredibly versatile manufacturing process capable of producing a wide range of products and components. Some of the most common types of products that can be manufactured using injection moulding include:
Consumer products – Everyday items like bottle caps, containers, kitchen utensils and toys are manufactured with this technique due to its cost-effectiveness and ability to replicate complex designs.
Automotive parts – Many automotive components including dashboards, bumpers, interior trim and engine components use plastic injection moulding in production to create durable and lightweight components.
Electronics – Plastic injection moulding is used to produce casings for electronic devices such as mobile phones, laptops, and gaming consoles and the variety of finishes available help to enhance the aesthetic appeal of the product.
Medical devices – Components for medical devices like syringes and IV catheters are created using plastic injection moulding as well as diagnostic equipment where precision and consistency are critical.
A plastic injection moulding machine is a specialised piece of equipment designed to inject molten plastic into a mould to create plastic parts with great accuracy. Some of its key components include an injection unit, a clamping unit and a mold which is a custom-designed tool that shapes the melted thermoplastic into the desired shape.
A plastic injection moulding machine works by heating the thermoplastic pellets fed into its barrel and melting them by using friction and heating bands. The clamping unit which holds the two halves of the mould together then closes, forming a tight seal. Once the mould is closed, molten plastic is injected into it at high pressure after which the mould is cooled down, causing the plastic to solidify. Finally, the mould is opened and the finished part is pushed out of the mould.
Many types of thermoplastics can be injection moulded with each of them having different properties best suited for various applications. Some of the most popular materials include ABS (Acrylonitrile Butadiene Styrene) which is great for durability and Nylon (such as Polyamide for example) that works well for wear resistance.
Other types of plastics that are commonly used in injection moulding include HDPE, LDPE, PBT and acetal, all of which find applications in industries ranging from automotive to medical manufacturing.
Learn about 8 of the most common plastics used in injection moulding in our full guide.
Choosing plastic injection moulding over other manufacturing processes offers several advantages, making it the preferred method in various industries. Some of the key advantages include:
- Cost-efficiency
- Superior precision and consistency
- Fast production cycles
- Design flexibility
- Reduced material waste
- Wide material selection
- Creates strong and durable products
- Scalable for both low-volume and high-volume production runs
- Reduced Tooling costs
- Applicable across many industries
- Consistent quality
At Fern Plastics, our injection moulding processes produce a minimal amount of waste and any plastic waste we create is recycled for other uses. Designing high-quality moulds and performing regular maintenance and inspections helps us to further reduce waste. Discover more about how we reduce waste in plastic injection moulding.
At Fern Plastics, quality control in plastic injection moulding is achieved through meticulous project management, thorough material inspection, precise mould design, and continuous process optimisation. For every project, a fully trained and experienced project manager is assigned to ensure consistency and quality are continuously maintained. Regular inspection during processes and quality control testing are used to detect any defects during production. The entire process is underpinned by our commitment to quality and continued improvement. The information from quality control measures is used to identify and rectify any issues so we can ensure the consistent production of high-quality plastic parts.
Our expertise in injection moulding allows us to accommodate custom mould designs with ease. We understand that each project may have unique requirements and our team is well equipped to work closely with clients to develop custom moulds tailored to their specific product design requirements. Whether its a complex shape, intricate designs or specialised features, we have the expertise and capabilities to design, fabricate and implement custom moulds that meet your exact specifications. Even if your moulds have been previously housed overseas and you’re interested in transferring them back to the UK, we can support you through the transfer process. Find out more about our plastic injection mould tooling.
We offer a range of value-added services that improve product appearance, remove aesthetic flaws and enhance the strength and durability of the final product. As well as providing comprehensive services for finishing, surface treatments and assembly, we offer quality assurance and flexible inventory management systems to ensure we provide a range of solutions that cater to all of your needs under one roof.