Plastic Injection Molding Service

APT-Mold is a rapidly growing enterprise in industrial area. We can offer you high precision parts from molds we build and maintain ourselves. The lead-times for our tooling is one of the best in the market, and our costs just can’t be beat. We will work closely with you to determine the most applicable tooling material based upon your anticipated annual needs, then provide complete DFM( Design For Manufacturability) recommendations to help you fine-tune your design for the most cost-effective parts possible.

APT Plastic Injection Molding – Rapid Tooling and Prototype

Are you looking for traditional injection molded parts in higher quantities? If so, APT Mold has you covered! We can offer you very high precision parts from molds we build and maintain ourselves. The lead-times for our tooling is the best in the market, far quicker than the traditional 8-12 weeks you’d find elsewhere, and our costs just can’t be beat. We will work closely with you to determine the most applicable tooling material based upon your anticipated annual needs, then provide complete DFM recommendations to help you fine-tune your design for the most cost-effective parts possible.

What is DFM?

DFM is an acronym for “Design For Manufacturability”. What that means is that we extensively study the 3D CAD files you provide and we make sure your design can be built as you intended. We then provide you a report for each part that summarizes the part information (size, weight, material, finish, color, etc.) and addresses any concerns regarding tooling or part design. Not only that, but our DFM also includes our recommendations on how to best resolve any issues to help you revise the design if necessary. All our DFM reports are created at no cost to you.

Draft Analysis

Wall thickness Analysis

Gating Quality Prediction

Process of Plastic Injection Molding

The injection molding process requires the use of an injection molding machine, raw plastic material, and a mold. The plastic is melted in the injection molding machine and then injected into the mold, where it cools and solidifies into the final part.

The process starts with plastic granules in a hopper. The granules are then moved from the hopper to a barrel, where they are heated to be a molten state.

Once the granules is melted, it is forced through the barrel by a reciprocating screw until there is enough material to fill the mould. The quantity of this material in one time is known as a shot.

After passing through a check valve, the shot of liquid material is forced from the barrel into a channel of the mould called a sprue, then through a network of smaller channels called runners and into the mould cavity.

The material begins to cool and harden once it reaches the mould by using cooling lines around the mould filled with circulating water. This way the product can be solid sooner.

When the material is fully cooled and solidified, the operator opens the mould, and the molded part can then be ejected automatically. When get the solid product from the mould, we cut all the runners and then a perfect product is appear.

The Materials of Plastic Injection Molding & Rapid Tooling?

That depends entirely on the quantity of parts needed. The higher the anticipated quantity, the harder the tool material must be to resist wear from numerous molding cycles. Although each case is unique, please refer to the table below as a starting point for what we may recommend for your particular parts:

Tool Life Tool materials Tool Lead Time
Low-volume Manufacturing 1,000-10,000  parts Aluminum or S50C steel 1-3 weeks for general tooling (may be slightly longer for more complex tools)
Medium-volume Manufacturing 10,000-100,000 parts P20 steel or 738H steel 2-4 weeks for general tooling (may be slightly longer for more complex tools)
High-volume Manufacturing 100,000-1,000,000 parts NAK80 or S136 steel 4-6 weeks for general tooling (may be slightly longer for more complex tools)

 

If I need really high quantities of parts, what steps do you take to assure my parts are as inexpensive as possible?
We look at many different ways to assure the lowest cost parts possible.

  • We use well-engineered cooling systems to reduce the cycle time.
  • Where applicable, we use multi-cavity tools to meet large volume capacity and reduce part cost.
  • We often use hot tip gates, sub gates, hook gates, and automatic cutting gates to reduce labor cost.
  • We have mechanical arms and conveyor belts installed on our Injection Molding Machines to help handle the molded parts automatically and efficiently.

Multi-cavity tools with hot tip gates

Conveyor belts

Advantage of Plastic Injection Molding 

At APT Mold, we have experience making highly cosmetic parts (exterior housings, lenses, etc.) as well as less visible mechanical parts (chassis, brackets, gears, etc.). We service markets ranging from industrial to home appliance, from automotive to consumer products, and from medical to scientific. There are many advantages in the process of plastic injection molding:

widely use

Widely in use

precession injection molding

Precision in size

Automation

Automated in process

reduction cost

Reduction in cost

Fast deliver

Fast deliver

Why Choose APT?

The world’s first-class injection molding  manufacturer. Why choose APT-mold?  Fast, Professional, Quality assurance… We alway provide the most comprehensive rapid tooling & injection molding services.

√ Technical Support

The support from APT team will help you shorten the lead time. And cost saving in new product development. We will support your project design for manufacturing.

√ Rapid lead time

The lead-times of our tooling is one of the best in the market. Usually for products with simple structure, we can finish the soft mold within 2-3 weeks, we can finish the production mold within 3-4 weeks.

√ Strict quality control

our goal is to come as close as possible to the golden standard of 100% perfect parts every time. Every product before delivery are under very strict quality control. We test the sizes and surfaces with high precision machines. And we make production records for every tooling in order to find the problem in the first place.

√Advanced Technology

Our rapid prototyping, Technology in Computer, Aided Design and Computer, Aided Manufacture also with experienced technician will make the parts in high quality for you.

√ Competitive price

We uphold the belief of reducing costs for our customers and extend our company. So we always quote the price with smallest profit and devote to keep more long term customers.

Do you have limits on the types of plastics materials you can mold?

Absolutely not. We can mold anything from inexpensive commodity resins like PP, HDPE, and styrene to engineering resins like PC, POM, nylon, and TPE all the way to ultra-performance materials like PEEK, polyimide, polysulfone, PPS, and more. And if your needs include fiberglass-reinforced resins, we can accommodate those as well.

material triangle

What about colors and finishes?

The ranges of finishes we can provide are almost limitless. We routinely polish our tools so that clear parts are truly transparent and we can take that one more step if optical-quality clear parts are required. We can also chemically etch our tools to replicate a wide variety of textured finishes, including selectively textured parts where some areas are textured while other areas remain gloss or matte. As far as colors go, if you provide a color chip, we can match it in most resins. We can also utilize overmolding to achieve both functional and cosmetic improvements.

surface finish

Applications for Plastic Injection Molding

Plastic injection molding are widely used on automobile, medical, industrial, daily necessary,etc. Almost all the product components forming processing need to use mould.

What tolerances can I expect from APT Mold?

Our general tolerances are in line with industry standards. We use ISO DIN 2768 (f) for precision-machined metal parts and ISO DIN 2768 (m) for machined plastic parts. We use DIN 16901 tolerance standards for plastic injection molded parts, unless 2D drawings with specific tolerances are supplied. If certain dimensions are more critical than others, those dimensions plus any manufacturing and technical specifications need to be clearly specified in the 2D drawings. Please refer to DIN 2768 and DIN 16901 standards.

plastic injection molding products
ISO-9001
ISO-9001

Quality Certifications

Proud to be certified by TÜV Rhineland and Dun & Bradstreet to the highest international standards. Check our quality certificates: IATF 16949 and ISO 9001.APT deliver costomer’s parts requirement quickly according to quality Certifications standard, contact us to get your parts quote.

Frequently Asked Questions About Plastic Injection Molding

How to Save Money with the Rapid Tooling Strategy?

The term rapid tooling is used just to describe the process which either used is into rapid prototyping techniques also. When it comes to creating a mold quickly you can seek the help of a rapid prototyping process. You just need to get a fabricator tool it takes less tooling time as well as cost in comparison to a conventional tool. So basically it can easily use to make multiple parts regarding the alternative materials. On the other hand, different types of rapid tooling processes also include different things like:

  • Composite injection
  • Kirike side injection
  • Silicone vacuum cast
  • Spray metal injection
  • Sand-cast
What are the Crucial Benefits of Rapid Tooling into an Organization?

Rapid authoring tools prove very worthy by completing the work quickly and easily. On the other hand, it turns out to be more successful in training making models more effective and delivering the best learning experiences. Generally, these software programs consider various multimedia elements within the respective animation’s illustrations, or even graphics. So, you have to consider the rapid too properly as it works into an organization.

When it comes to comparing these tools, you have to consider numerous other things also. They surely offer you more benefits and surpass all the advantages. Numerous key benefits are mentioned below:

Surely saves your time and consider training cost

Rapid tooling is a proper process that reduces the cost as well as the time that is involved in the development courses. They also get any additional software and their interfaces regarding the media elements. This makes all the creating courses very fast and easy you have to consider all the rapid tooling system properly to get extra benefits.

Increase performance

You need to keep track of the learner’s performance as it has been a great factor to determine the learning experience. Learning always plays a crucial role for the learners to pursue their convenience from anywhere. If you want to make the track easier you have to work according to the module. It surely works to enhance performance in the module.

Transforms existing courses

You need to keep real Track of all the learners’ performance. It has always been a great factor to determine the learning experience for early learning. It allows the learners towards it. This will have their convenience to get extra advantages. When it comes to making it using you can track the overall performance. So you have to manage all the things into the digital format as these slides, images, and presentations can be considered for repair that includes up-to-date information also.

Available on all platforms

Learners can easily process a hassle-free experience by getting details about the module. However, when you want to desire to get an irrespective location you have to search a lot of the best part about it. You have to use rapid tools according to the learning. In addition, you can consider HTML-based courses that are accessible on different types of platforms including laptop, desktop, and mobile devices.

Globalisation of e courses

You need to develop an online course as it is also an intimidating task that should be considered. Therefore these tools always provide real control over the development of the training courses.

These are many benefits that you will get with the rapid tooling process. However, the key is to get really as per according to all the needs. When you need to develop and maintain all the e-learning courses continuously you have to seek out the help of an expert.

How Rapid Prototyping is Considered Useful for the Industries?

There are numerous benefits of rapid prototyping in various Industries that are given below:

Get changes

To show a 3D model to the client regarding the cost obviously, allows you to learn about various problems. With the help of models, it is not possible to do so. If you consider 2D model wallpaper for the testing then you have to face a lot of consequences also. This makes your overall feedback possible and gets changes accordingly. So whenever you want to manage your rapid prototyping process properly you have to learn about what customers want.

Conceptualization

You seriously need to realize the exact things behind a design. Product designers need to visualize the final product. On the other hand, one can take a look at the final production model. As they can easily analyze the final product also the entire process depends on the designers as you have to take a look towards the final product only then it allows you to make the necessary changes.

Customization

When you consider the rapid prototyping process it doesn’t require more kinds of special tools and equipment. One can easily get the process to create an extra type of prototype without including anything into it. This surely allows you the best things regarding the designers as you can create models according to the choice of the customers and clients. It not only allows you certain connectivity regarding the process of manufacturing but provides extra advantages also.

Cost and time-efficient

The process of creating tools for a certain design should be eliminated in rapid prototyping. In this process, you need to use very less tools. As it reduces the cost of the processor it also reduces the time effectively. So when it comes to considering certain requirements like CAD software and printing machines one can easily use it to create various types of sizes and shapes.

Lesser flows

One easily gets the proper amount of money and time on a large scale but you have to minimize the flaws according to the prototype level. The resources and materials that should use in the rapid prototyping from as similar to the final material.

What Are the Proper Rapid Prototyping Services?

Considers professionalism

Apart from enjoying different services, you need to consider everything professionally. For example, if you choose good companies that have a reliable team of prototyping engineers office a kind of durable kind of benefits. You have Real Experience to handle all the customer needs that including advising customers on the best process materials and even finishing the project properly; you can easily tell how professional and perfect the team that works on your project is. Make sure that you have to check out the responses. Generally, you need to consider the overall process as it handles your work.

Includes technological advancement

To get desired results you seriously need to configure a rapid prototyping company. They can offer you up-to-date services according to the Machines and Technology. Always remember the machine and the prototyping techniques can easily determine the results that can easily enjoy. So you have to determine the manufacturing capabilities also of the company especially of the large products ensure that your service provider uses materials and machines regarding accuracy. So you have to manage out all the tough products at the end that should match all your needs. Once you are able to fulfill all your needs it makes your life proper.

Quality of turnaround system

This is the best thing about rapid prototyping as it greatly minimizes the entire time. So whenever you want to get desired results and other specifications you need to choose the perfect company. They can deliver your all models within the stipulated time ensure all your projects that get lower down or not. Apart from having more information regarding the models you can choose the proper company that should offer you quality results. On the other hand, you need to consider how qualified and skilful the workers are to offer you real services. To gain extra confidence you need to make your business more productive.

How about the lead time for APT Tooling?

The lead-times of our tooling is one of the best in the market. Usually for products with simple structure, we can finish the soft mould within 2-3 weeks, we can finish the production mould within 3-4 weeks.

What about colors and finishes?

The ranges of finishes we can provide are almost limitless. We routinely polish our tools so that clear parts are truly transparent and we can take that one more step if optical-quality clear parts are required. We can also chemically etch our tools to replicate a wide variety of textured finishes, including selectively textured parts where some areas are textured while other areas remain gloss or matte. As far as colors go, if you provide a color chip, we can match it in most resins. We can also utilize overmolding to achieve both functional and cosmetic improvements.

Do you have limits on the types of plastics materials you can mold?

Absolutely not. We can mold anything from inexpensive commodity resins like PP, HDPE, and styrene to engineering resins like PC, POM, nylon, and TPE all the way to ultra-performance materials like PEEK, polyimide, polysulfone, PPS, and more. And if your needs include fiberglass-reinforced resins, we can accommodate those as well.

What is overmolding?

Over-molding is a common process in injection molding for specific uses. There are three general over-molding approaches:

  • Metal part insert-molded into rigid plastic, such as brassnuts insert-molded into a plastic housing —used for screw assembling
  • Soft material over-molded onto rigid plastic, such as TPE (thermoplastic elastomer) over-mold on ABS or ABS/PC material — used for soft touch grips, switch buttons, sealing, etc.
  • Rigid plastic over-molded onto rigid plastic, such as ABS over-mold on clear Polycarbonate — used to combine opaque and transparent functions in one part.

APT Mold has experience with all three types of overmolding and we can help determine if this process is right for your particular needs.

Can you paint and print graphics on our parts?

Yes, we have full painting capabilities for those cases where molded-in color is not feasible, including the ability to mask portions of a part to create two-tone finishes. We can also add the final touch by printing graphics directly from your artwork via pad printing or screen printing onto the finished cosmetic surface, whether molded or painted. We can also include graphics by adding a separate printed label or overlay.

Sample Our Work

At  APT Mold, we have experience making highly cosmetic parts (exterior housings, lenses, etc.) as well as less visible mechanical parts (chassis, brackets, gears, etc.). We service markets ranging from industrial to home appliance, from automotive to consumer products, and from medical to scientific.

Please review the following portfolio of parts and products to see the breadth and quality of our work.

View Over-molded parts

Electronic product housing
(Clear PC over-mold with ABS)
Material: PC/ABS
Finish: Glossy/Texture
Dimension(mm): 115x80x12

Sanitary product cover
(Brass nut insert-mould in plastic)
Material: ABS
Finish: Texture
Dimension(mm): 230x230x90

Air conditioner screen plate
(Nylon net mould on PP)
Material: PP
Finish: Polishing(SPI A-3)
Dimension(mm): 200x160x10

Clear parts

Housing for cosmetic
Material: PC
Finish: High polished
Dimension(mm): 67x67x28

Lighting reflector
Material: PMMA
Finish: High polished
Dimension(mm): 150x130x60

Clear cover
Material: PC
Finish: High polished
Dimension(mm): 91x95x30

Parts in a wide variety of materials

Plastic housing
Material: PC
Finish: High gloss and Painting
Dimension(mm): 160x80x50

Structure component
Material: PPS
Finish: Smooth(SPI B-1)
Dimension(mm): 60x60x50

Plastic tube
Material: HDPE
Finish: Smooth(SPI B-1)
Dimension(mm): 180x25x25

Decorated parts

Plastic cover
Material: PC
Finish: Metallic Painting
Dimension(mm): 170x140x80

Plastic shell
Material: Translucent PC
Finish: High gloss and pad printing
Dimension(mm): 160x120x50

Lighting component
Material: PC
Finish: High gloss and electroplating
Dimension(mm): 100x100x80

Technical Support

The support from APT team will help you shorten the lead time and cost saving in new product development. We will support your project design for manufacturing.

Innovative Ideas

We have innovative ideas based on design. Our manufacturing experience will help you trouble shooting and turn your idea into reality, get things done.

Advanced Technology

Our rapid prototyping technology in Computer Aided Design(CAD) and Computer Aided Manufacturing(CAM) also with experienced technician will make the parts in high quality.

 

Fast Response

We keep a close eyes on your every project, you will usually receive our quotation and get a reply for project within 24 hours.

What is Your Next Step?

This will guide you through our very simple quote submission process. We are excited for the chance to earn your business!