From Design to Delivery: How an Injection Molding Turnkey Solution Works

Let’s talk about thermoplastic injection molding — not just about the quality, or the cost value or fast turnaround. 

 

We’d like to take a deep dive into the complete plastic injection molding process — from design all the way to packaging and shipping. Utilizing a turnkey solution ensures that the material and mold is the perfect fit for your product.

 

Check out the steps and illustrations below that answer the real question at hand: how does it actually work?

 

Step 1: Mold Design.

The mold design for any tool is essential, and it’s part of why injection molding has an up-front tooling cost. Working with designers and engineers, we develop a custom mold for the part being produced. 

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This, in combination with specialized injection molding processes, allows for a great deal of design freedom — complex shapes and unique features can be accommodated with special cores and molding systems. Overloading and insert molding can even mold one part directly onto another in a single cycle. 

 

Step 2: Select raw materials.

We often emphasize the importance of material choice with our customers, because injection molding has a unique advantage in that it works with a wide variety of raw materials. Metals, glasses, elastomers, and confections can all undergo this process, though it’s most commonly associated with our specialty: thermoplastic and thermosetting polymers.

These materials begin the process in a raw, solid state, and are then heated to the desired temperature. This process melts the material so that it can be applied to the corresponding mold.

 

Step 3: High-pressure injection.

The now-molten material is placed under high pressure and injected into the center, or cavity, of a mold. A rotary screw mechanism dispenses a carefully engineered amount of material to minimize waste while still achieve a uniform coating.

The high pressure also ensures that material flows through the mold appropriately — without it, the liquid may not flow into every part of the cavity, which would create defects.

 

Step 4: Cooling.

After molding, the part must cool and cure. The dimensions of the new part actually become stable within the mold; if released prematurely, it could be exposed to inherent stresses that can cause deformation. 

 

Step 5: Release.

Once the molten plastic solidifies, the molds are separated to release the product. The molds are then reseated, new material is injected, and the cycle begins again. 

 

Step 6: Package and ship.

Full-service companies like K&B can also assist in the final packaging of your parts. K&B offers inventory management as a value-added service as part of its design-to-shipping turnkey solution. 

After the design is designed and manufactured, customers can send K&B their copies of part orders, and K&B sends the product to distributors country-wide. We then notify customers when their part has shipped, and invoice the distributors for the shipping service.

 

To learn more about thermoplastic injection molding or our services at K&B Molded Products, check out our eBook: The Benefits of Using a Turnkey Manufacturer.

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