Injection molding is the most cost-effective way to make a plastic part at scale. The injection molding process involves injecting molten plastic into a mold tool, then ejecting the solidified part. This process quickly repeats hundreds or thousands of times, amortizing the cost of the mold tool and driving down the cost of each unit to a few dollars or less. Since the injection molding process uses the same mold tool for each part, it offers consistent quality across every part. Injection molding also has the highest variety of materials, colors, cosmetics, polishes, and surface textures when compared to CNC machining or even 3D printing.
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Xometry's custom plastic mold service is a service providing on-demand prototype and production molding. We take a customer-first approach which means we find the right injection molding supplier within our manufacturing supplier network to mold the parts the way you need them&#;without design compromises&#;at the right price point. We offer expert consultation on each injection mold quote and project managers on every order to move your parts from design to production. Our team has experience in every industry, especially medical injection molding and liquid silicone rubber molding. First-time buyers receive $500 off their first mold with Xometry. We offer both domestic and China injection molding options, as well as ITAR injection molding.
Injection molds, or mold tooling, are the formed halves of a metal mold that come together in the injection-molding machine. The cavity in the mold is then filled with molten plastic. Each mold will have two sides, Side A and Side B or the Cavity and the Core. The cavity side, or Side A, is typically the half that will form the best surface of the part. The core side, or Side B, may show some visual imperfections caused by ejector pins. The ejector pins are used to knock the part out of the mold so the next part can be made.
Injection molds are typically made with Computer Numerical Control (CNC) machining or with Electrical Discharge Machining (EDM). Traditional machining used to be the standard method of building injection molds. Those molds were carved out of metal blocks with a knee mill. Technology has since replaced traditional machining, giving way to CNC machining and EDM. CNC machining and EDM allow for more complex molds and accurate detailing while taking less time to make than traditional machining.
EDM is the newest way to make plastic injection molds. The process uses a shaped, copper or graphite electrode. The electrode is slowly lowered onto the mold surface that is immersed in paraffin oil. Electric voltage applied between the tool and the mold causes spark erosion of the mold surface in the inverse shape of the electrode. EDM is essentially a high-tech machining method that uses electricity to melt away material. The mold is immersed in oil so that any removed material will harden before re-adhering to the mold surface. EDM allows plastic injection mold makers to achieve a level of detail that would be impossible with traditional methods like milling or grinding.
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EDM has become widely used in mold making industry. Many companies, including ICOMold by Fathom, offer in-house EDM services. The process allows the creation of molds that would otherwise be difficult or impossible to machine in a conventional manner. Details like ribs or square corners are easily done with EDM but nearly impossible with even the most advanced CNC machining.
EDM can only be used on electrically conducive materials. This allows pre-hardened steel molds to be shaped without requiring a follow up heat treatment.&#;Molds can be made of pre-hardened steel, steel that is hardened after the mold is produced, aluminum, and/or beryllium-copper alloy. The number of parts being produced typically determines the choice of mold material, although there are a few variables to consider.
Steel molds will generally have a longer lifespan. The higher initial cost of a steel mold will be offset by longevity, as it is capable of producing a higher number of parts before wearing out. Pre-hardened steel injection molds are less wear-resistant than those hardened by heat treatments after they are machined. Pre-hardened steel is typically used in molds that have a lower volume part requirement.&#;Steel molds can also be modified or repaired to extend longevity, an advantage not shared by aluminum molds.
Aluminum molds, depending on varying economic conditions and material origin, can cost substantially less than steel molds. Aluminum molds have a quick build&#;time, and give faster cycle times due to the heat dissipation properties of the metal. Beryllium copper can also be used in areas of the injection molds that require fast heat removal, or in areas where the most shear heat is generated.&#;Longevity and durability are an issue with aluminum molds and beryllium copper molds since both are softer metals than steel. Aluminum and beryllium copper molds will need to be replace much quicker than steel molds. Aluminum and beryllium molds also cannot be repaired or modified after machining where as steel molds can be repaired or modified to some extent.
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