Custom Injection Molding: Higher Quality Parts at Lower Cost
Complex, critical-use parts are hard to make because they often involve challenging shapes, sizes, and materials. Many custom injection molders simply don’t have the expertise, equipment, or know-how to make these components.
This is where Kaysun comes in. We specialize in making custom, critical-use plastic parts or products with tolerances as tight as .001 inches.
This advanced level of injection molding relies on our deep knowledge of material science and advanced injection molding equipment and controls. Our plastic injection molding process is ideal for making high-performance, complex products from multiple materials that require the highest precision.
Complex custom plastic injection molding relies on multiple scientific methods, analytical tools, and molding process technologies to achieve the performance requirements for critical-use plastic components. This approach optimizes the four key stages of product development:
It is most beneficial to start a custom plastic injection molding project early in the design phase, when adjustments can be made easily without having a significant effect on total costs and product timeline. This is where all options are considered to maximize the product’s design for manufacturability.
Material selection is one of the most critical steps in complex custom plastic injection molding. As critical-use products become more complex, designs increasingly require multiple materials. These polymers must be compatible over a range of conditions to ensure permanent bonding and flawless performance. During the plastic injection molding process, the molten plastics are monitored using sensors in the mold cavity that measure parameters like pressure and temperature. If needed, adjustments can be made in real time during the molding process to make sure that high-quality products are consistently produced.
Depending on product design and end use, molding technologies that are utilized during complex custom injection molding include scientific molding, insert molding, multishot molding, and overmolding. For example, overmolding adds a soft-touch exterior to products that enhances grip and provides a stylish appearance that’s attractive to consumers. It also reduces shock and vibration, dampens sound, provides electrical insulation, and improves chemical/UV resistance—all of which increase product longevity.
The custom plastic injection molding process can be customized for any project to maximize quality and manufacturability. It starts with communication—in order to design the best possible process, we must understand, at a deep and holistic level, the client’s vision for the product. Perhaps most important, our plastic injection molding process gives engineers the design freedom to create new features and more advanced products. By streamlining the production process and speeding up production, custom injection molding results in higher quality, lower costs, and satisfied clients.