In many industries, injection molding is a proven solution to complex plastic part engineering and design challenges. However, not all projects are well-suited for the process and will not fully benefit from injection molding efficiencies.

When it comes to designing and launching a new product or component, there are three things design engineers can always count on:

Complex injection molding is relied upon in a number of industries to make the production of plastic parts and products more efficient. Crucial to realizing this efficiency though, are design and manufacturing process improvements that allow for the consolidation of multiple existing parts into a single complex injection molded plastic component. Below are examples that demonstrate the benefits of part consolidation and how to achieve them:

Little things matter when it comes to overall efficiency, productivity and quality. Of course, having the best equipment and technologies, materials, know-how and training is a given. But efficiency and productivity are generally always enhanced when injection molders and their customers know each other well as partners and work together as a team. They share the same strategies. Each knows how the other thinks and operates. The relationship deepens over the long term because they know they are stronger together.

Moldflow analysis is a frequently used term in the injection molding industry but it is often poorly understood. The process uses a sophisticated computer program to analyze and predict the flow and cooling of plastic during all phases of the injection molding process. Since there are different levels of analytical software available, selecting the right one for your project is as important as interpreting the data for successful results.

In this age of global competitiveness and tough regulation, superior quality is the name of the game in differentiating you from competitors and increasing your market share.

OEMs in various industries are designing increasingly complex components, products and devices with higher injection molding tolerances that must meet stringent quality standards, regulatory compliance and cost-effectiveness. This can be achieved through scientific molding, the best designed and controlled manufacturing process possible.

Metal-to-plastic conversion is a decades old concept, and it remains a popular option for addressing concerns about component or end product cost, weight, manufacturability and compliance. While metal-to-plastic conversion is effective, many industries — notably automotive, defense and medical — are leaning into it further in order to reap more benefits by consolidating multiple existing parts into a single complex injection molded plastic part.

There are many factors that impact injection molding tolerances—all of which need to be controlled with precision to meet final part specifications. The greater the number of factors, the harder it is to achieve tight tolerances consistently. That’s why it is so important to consider tight-tolerance requirements during the plastic part design process, where factors can be addressed through design modifications without impacting quality or performance. In fact, working with an experienced injection molder like Kaysun could actually result in even tighter tolerances, if needed, through expert alignment of design, materials, tooling and production process parameters.

Medical grade polymers are quickly becoming the preferred material for a broad range of surgical devices. In certain applications, the robust mechanical properties of medical molding polymers allow complete removal of metal from the surgical device design. In other instances, plastic and metal components can combine to create an enhanced product, with attributes that would not be possible in either an all-metal or an all-plastic device.