black pellets

 

Custom Plastic Injection Molding

We specialize in custom injection molding of special thermoplastic, thermosetting, and composite materials.

 

 

Custom Plastic Injection Molding

Overview

Custom injection molding materials can be selected to meet or exceed your specifications and enhance your products performance properties, such as appearance, durability, chemical resistance and corrosion resistance.

Injection molding is a manufacturing process that creates objects by injecting a desired material into a custom-designed mold.  It is the most preferred method for producing high volumes of plastic parts and products.   Injection molding has an infinite number of applications.  It is used to create bottle caps, automotive parts, wire spools, storage containers, one-piece furniture, and most other plastic products.

Manufacturers can use a variety of materials in injection molding.  The most common are thermoplastic resins and thermosetting polymers, but elastomers, types of glass and metals (though this process is referred to as die-casting) can also be used.  One of the most versatile and popular resins used for injection molding are PEEK plastic, also known as polyetheretherketon and TORLON.

Thermoplastic is the best material used for injection molding because of its versatility.  Not only does it easily soften and flow into molds when heated, it is generally more forgiving than other materials.  Thermosetting polymers, for example, need to be used quickly after heating.  If not, it can seize and damage injection molding machines.

Injection molds are typically made from tool steels, however, stainless steel or aluminum molds may be better suited for certain applications.  Aluminum molds are more susceptible to deformation during injection and clamping cycles, and therefore aren’t suitable for high-yield jobs.  Steel molds are far more expensive but have impressive durability, capable of producing upwards of a million items in their lifespan.

For custom molding with thermoplastic resins, raw pellets of material are fed into a heated barrel with a reciprocating screw.  As the temperature of the barrel increases, the viscosity—or thickness—of the pellets decreases, which enables it to travel through the check valve and creates a shot.

A shot is the volume of material needed to fill the cavity of the mold.  The material is forced in the mold, allowing for the shrinkage when set.  Finally, the items are efficiently chilled by the external temperature controller and a series of lines that circulating chilled water or oil around the molds.  Once the desired temperature is achieved, the molds open and the parts are removed by pins or strippers, so the entire process can be repeated.

Benefits:

  • There are infinite options for injection molding, including adding molded in color. Aztec Plastic has manufactured a vast variety of products in varying sizes, materials and colors in our 40 years of business.  We specialize in custom injection molding of special thermoplastic, thermosetting, and composite materials. These materials can be selected to meet or exceed your specifications and enhance your products performance properties, such as appearance, durability, chemical resistance and corrosion resistance.
  • Injection molding produces little waste, which makes it a cost-effective manufacturing process.  Any unused materials can be re-purposed for future use.
  • This process produces high yields of products in very little time, which reduces cost of labor.
  • The process can be used with lighter plastics, which can replace expensive and heavier metals. 
  • There are several different types of injection molding, which means there is a variety of ways to produce your custom products.  Die casting is an injection molding process for most metals.  Die cast molds are made from non-ferrous metals.  Thin wall injection molding is a specialized type of injection molding that focuses on saving money by using less materials and shorter cycle times.  It does produce a lighter, thinner product.  Reaction injection molding requires a curing process that occurs within the mold.
  • Aztec Plastic has extensive experience in EMI and EFI shielding, and we specialize in metal replacement in hydraulic and pneumatic valves such as poppets and spools.
     

The Aztec Advantage

We specialize in custom injection molding, including the designing and production of molds.

In 2017, we have produced dozens of products include the Batmobile and Black Panther Masks, which were made with PEEK injection molding and maching torlon, respectively. In May 2015, we completed a run of custom game pieces for a local Wisconsin trivia game called On Wisconsin.  The pieces (pictured above) were produced with the following processes and  ipsum dolor sit amet, consectetur adipiscing elit. Duis feugiat turpis velit, sodales fermentum orci ultricies sed. Sed id hendrerit diam. Integer elementum ultrices neque vitae porta. Duis mollis sed libero vel volutpat. Interdum et malesuada fames ac ante ipsum primis in faucibus. 

Hear from our Clients

“They are a very high end molder… can do complicated, high temp specialty engineering products. They do a lot of things other molders will not do.”

Hear from our Clients

“They’re not scared to take on the hard jobs. Always willing to go the extra bid and willing to stay no if they can’t do it… they are willing to be a better supplier…

Please contact us if you have any questions about our services. 

 

First Name:*        

 

Last Name:*        

 

Email Address: 

 

Phone Number:* 

 

Contact Me By:*  Phone  Email

 

Comments: 

 

 

top