FMS provides the most cost-effective injection molding service
FMS offers high quality on-demand injection molded parts. Injection molding is the cheapest process for producing plastic parts that provides consistent quality for mid volume to high volume production. Compared with CNC machining and even 3D printing, injection molding has the most abundant materials, colors and configurations. In addition to material, injection molded parts can also have custom cosmetics, polishes, or surface textures.
FMS often uses some unconventional solutions for injection molding to meet the special requirements of customers. We even design special auxiliary equipment for injection molding machines to meet the special requirements of our customers’ projects, and we are willing to challenge complex projects. Any customer who cooperates with us will have an unprecedented sense of accomplishment. Our goal is to provide a long-term solution, apply molding technology to the maximum limit, and work with full-time project managers and engineering experts in all projects from design to production. Plastic injection molding is a manufacturing process used to produce a large number of plastic parts. Usually used when thousands or even millions of identical parts are created consecutively.
FMS has been providing mold and injection molding solutions to companies from all over the world since 2009. We have completed customized plastic injection molding projects for medical, automotive, sports, hunting/camping, electronics, food/beverage, container, packaging and other industries.
We take pride in our superb injection molding technology. All FMS molds and production equipment are under the control of FMS team. Our injection molding workshop runs three shifts a day, five days a week, and overtime on weekend is based on production needs to determine whether overtime is required. All our injection molding machines are equipped with robots for high-speed automation and injection production.
Customers trust FMS and recognize FMS as an expert in injection molding services in the engineering and manufacturing sectors. Our injection molding and mold engineers have extensive expertise and production experience, and have participated in the design and molding of products and components in many industries.
Injection molding is the most common modern method of manufacturing plastic parts. It is used to make various parts with different shapes and sizes, and is ideal for mass production of the same plastic parts. Injection molding is widely used to make a variety of parts, from the smallest medical device components to the entire body panel of a car. Injection molding is a manufacturing process that can use both thermoplastic and thermoset materials to produce plastic parts. It can produce parts with complex geometries that are not possible with many other processes.
There are thousands of designers who design injection molded parts but there is an elite group within this large community who can actually design parts for injection molders. Injection molded product design evolves through many phases of development before all the parts are ultimately documented and released to a molder for production. This last step in the development process is the most critical, since design changes or corrections can no longer be made without significantly adding cost or project delays.Unfortunately, plastic part design mistakes will be uncovered only after first article parts are inspected and evaluated by the project team. Even with today’s sophisticated mold flow simulation, 3D CAD interference checks, rapid prototyping and numerous other development tools, it is impossible for anyone to predict every potential problem for an injection molded part. However, there is a very simple, low-cost method for minimizing potential problems and virtually ensuring perfect parts. It’s called partnering with your molder.
It doesn’t matter how well you think you know how to properly design parts for injection molding—you should always form a close partnership with your preferred molder as early in the design process as possible. Every molder has his or her own tooling preferences and techniques for molding parts, which can have a significant effect on part design. These subjective preferences can influence any of the following major design-related parameters affecting an injection molded part.
Before you endeavor to produce a part via injection molding consider a few of the following things:
Financial Considerations
Entry Cost: Preparing a product for injection molded manufacturing requires a large initial investment. Make sure you understand this crucial point up front.
Production Quantity
Determine the number of parts produced at which injection molding becomes the most cost effective method of manufacturing
Determine the number of parts produced at which you expect to break even on your investment (consider the costs of design, testing, production, assembly, marketing, and distribution as well as the expected price point for sales). Build in a conservative margin.
Design Considerations
Part Design: You want to design the part from day one with injection molding in mind. Simplifying geometry and minimizing the number of parts early on will pay dividends down the road.
Tool Design: Make sure to design the mold tool to prevent defects during production. For a list of 10 common injection molding defects and how to fix or prevent them read here. Consider gate locations and run simulations using moldflow software like Solidworks Plastics.
Production Considerations
Cycle Time: Minimize cycle time in as much as it is possible. Using machines with hot runner technology will help as will well-thought-out tooling. Small changes can make a big difference and cutting a few seconds from your cycle time can translate into big savings when you’re producing millions of parts.
Assembly: Design your part to minimize assembly. Much of the reason injection molding is done in southeast Asia is the cost of assembling simple parts during an injection molding run. To the extent that you can design assembly out of the process you will save significant money on the cost of labor.
Injection moulding (U.S. spelling: injection molding) is a manufacturing process for producing parts by injecting molten material into a mould, or mold. Injection moulding can be performed with a host of materials mainly including metals (for which the process is called die-casting), glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed (using a helical shaped screw), and injected into a mould cavity, where it cools and hardens to the configuration of the cavity. After a product is designed, usually by an industrial designer or an engineer, moulds are made by a mould-maker (or toolmaker) from metal, usually either steel or aluminium, and precision-machined to form the features of the desired part. Injection moulding is widely used for manufacturing a variety of parts, from the smallest components to entire body panels of cars. Advances in 3D printing technology, using photopolymers that do not melt during the injection moulding of some lower temperature thermoplastics, can be used for some simple injection moulds.
The plastic injection molding process is generally dated back to 1868, when John Wesley Hyatt of billiard ball maker Phelan and Collander was searching for a suitable replacement material for the ivory in billiard balls. Hyatt invented a way to inject celluloid into a mould that processed it into a finished form. In 1872 John and his brother Isaiah patented the first injection molding machine. This machine was relatively simple compared to the complex machines used by today’s injection molding companies. It consisted of a basic plunger to inject the plastic into a mold through a heated cylinder. The industry was slow to adopt the injection molding process, eventually beginning to produce plastic items such as collar stays, buttons and hair combs. Not until the 1940s did the concept of injection molding really grow in popularity because World War II created a huge demand for inexpensive, mass-produced products.
Although the manufacturing of plastic products using an injection mould may seem quite simple at first (the plastic material is injected into a mould, left to cool, then removed when ready) there are however more complex steps involved in order for this seemingly simple process to occur. The six main steps are as follows:
Clamping – the clamp unit consists of metal plates (or platen). The process begins with the mould being clamped together under pressure to accommodate the injection and cooling processes.
Injection – the molten thermoplastic material, which has been melted by pellet form in the barrel of the machine, is injected under pressure into the mould through either a screw or ramming device.
Dwelling – once the molten plastic is injected into the mould, more pressure is exerted to make sure all the mould’s cavities are filled, using hydraulic or mechanical pressure.
Cooling – the plastic is left to cool and solidify within the mould.
Opening – the movable platen is separated from the fixed platen to separate the mould.
Ejection – ejection is completed by the use of rods, a plate or an air blast to remove the plastic component completely from the mould.
When looking for a company to assist you with your plastics manufacturing, make sure you understand the processes they use so you can get a better idea of how they operate and what you can expect from the finished product. Some manufacturers will allow you to take a tour of their facility and many will have videos and other useful production information posted on their website.
Don’t be afraid to ask your manufacturer about the injection moulding process – a few questions at the start will go a long way towards ensuring you get the best results.
The biggest advantage of injection molding has to be its low production costs as plastic product designs created this way have very low price per unit compared to other plastic production following a different type of manufacturing technology. Its ability for mass production defeats the costs of materials since everything is in a lump amount making it cheaper overall. However, be reminded of the setup’s cost and tooling as well to balance its cost effectiveness.
Injection molding is a manufacturing process used on a wide variety of products from tiny components up to large items. It is popularly used in the plastics manufacturing industry. The process uses a granular plastic gravity fed from a hopper which is dumped into a heated chamber through a screw-type plunger. The plastic is melted while pressed against the mold. The object is allowed to cool and is removed as a solid product. In some aspects of manufacturing, aluminum molds are also being used since they are quick to mass produce while other large manufacturing companies use steel molds of various kinds. It depends on for how long or better for how many pieces the mold has to last.
Most traditional plastic manufacturing processes cut out a substantial part of its plastic sheet during production. With injection molding, scraps and wastes only come from overflows in the mold and leaks from runners and sprue. Injection molding follows cuts accurately keeping wastes at an all-time low in plastics manufacturing.
Injection molding makes it possible to produce plastic product designs in large volumes which is why it is popularly used in large-scale plastic custom manufacturing. Thousands of plastic part designs can quickly be manufactured after several hours of work in a manufacturing production line. The main disadvantage of injection molding is that the process is not suitable for very small-scale production given the setup costs and equipment needed for this type of technology.
When you use a project broker, you will find that you save a lot of time and money when you look at the cost of the entire project, for example, you can free up time to develop other projects and reduce unnecessary travel expenses. Everything is so easy, if you want to choose a direct supplier, there are a lot of things you can’t know, because no one will tell you about the real situation of your project. I have a deep understanding of this, and since I worked with First-rate mold solution company, I really appreciate the benefits of using a project broker.
I think that with the development of Internet technology, the way of making the offshore mould will become more and more popular.
In fact, the management mode of each company is different, depending on the specific situation of each company, we can discuss together.
your process about running an offshore mold project is perfect! thanks for sharing
project management is very important in offshore mold making
Very good blog! thanks for sharing your experience
l like any useful content
it seems that you can do a good job, because of your very good project management system
Good process! I read to tҺis aricle on your website, It is very helpful for me
project management is a system engineering
it is not easy to make a good project management, especially for offshore project
your project management is very good, but different mold company has their own problem, we can discuss it
your project management process is very good
your process is perfect!:-)
Amazing process, I think you can a good job by this system
I think your project management is a perfect solution.
I think this is a good topic, it is worth discussing
your mold project management system is very good, I think we can discuss something about it
actually offshore project is not easy to control, you found a good process
I think that is an important sharing
Your project management system can make a good demonstration for some mould companies
a good project management team need some excellent mold engineers
we should learn from you in offshore project management. you really do a job in this field
I can see your major business are offshore project. I believe that you can do a good job for your customers
it seems that we can discuss some issues about project management
it is not easy to do a good project management
However project management is very important for every mould project
project management is not easy to do, Because you never know what will happen in the next step
project management is a professional job,It requires that every project engineer must master the relevant professional knowledge and working experience
project management is very important. your ideal in this field is very good
we have some experience in mold project management, maybe we can discuss
Welcome to discuss the problems you are interested in
your mold project management system is fine
we have a project department to do these things
in my opinion, your project management system is very good
your project management system is better than ours, we should learn from you
in the future, the mold will be replaced by 3 d printing
according to your project management process, you can do a good job for your customers.
project management need an excellent technical team
Project engineer technology literacy is very important
there is a different project management system for different company and different customer from different country
With the development of Internet technology, I’m bullish on this model, because…Do you know what I mean:-)
I think your company is a company which provides all kind of professional services for oversea customer’s products
Generally, Project Management is the guarantee of product quality
Your project management processes and ours are very similar, maybe we can discuss each other
when making moulds for a new project, project engineers are very important, it seems that your company has a good project management process
I am a mould engineer from Russia, your project management process is fine.
Your project management system seems perfect, I want to try to let you do my products, I will contact you soon
from the process of your Project management , I didn’t find anything special
Hello my friend, thanks for you share your project management process, actually, The same thing will follow the same rule
Your project management process is similar with ours, but need to add some details to make sure everything is OK! we can discuss later:-)
thanks for sharing your management process, We also have a good management process
One major advantage of your company is that you have a perfect project management process.
It’s impressive that we are getting ideas from this article, we do the same thing and discuss together:-）cheer!
The key of Your Project management is your detail management
I think we can discuss this topic here, because Our project management system and your system has some different
thanks! we are glad to do that
thanks for telling me your project management system, actually,Detail management is the most difficult
This is just a rough process， the ability to deal with emergencies is the most important part for a project engineer
I think I can learn some from your project management process, thanks
I think we should learn from you, your project Management system is very scientific
I have been reading out a few of your articles and i should say nice stuff.
I’ll certainly bookmark your blog.
Superb article from specialist. now I work in a mold company, I wish this website can Enlarge my knowledge， Thank you a lot for writing this helpful info for us all.
Project management is a technical job, as a mold project engineer, he should master the overall manufacturing process to make sure workshop do a good job. I believe first-rate mold solution limited company has an excellent team
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