Prototype Injection Molding

Inox Prototype Injection Molding

InoxCast is a world-leading provider of prototype injection molding for a wide range of applications throughout most major industry sectors.

InoxCast prototype injection molds are designed to produce functional testing of real injection molded parts. This molding can also be served as bridge tooling to fulfill the manufacturing gap for production tooling.

With over 15 years in the industry, we gained expertise especially in the material we utilized. It mainly includes large in-house material selection, sourcing services and custom material selection, and custom any colors.

InoxCast has obtained a good reputation as the world-leading provider of prototype injection molding by supporting our customers throughout a wide range of industries with specific requirements.

InoxCast prototype injection molding is in fact popular in many sectors across the world, from medical devices, consumer products, industrial equipment, defense, aerospace, computer and electronics, automotive, agriculture, and energy.

InoxCast is your one-stop partner for prototype injection molding considering that InoxCast, as a manufacturer, we design, analyze, and manufacture injection mold parts in-house.

You can work directly with our project engineers, designers, and molding experts to make your project done.

InoxCast company is equipped with advanced machines, qualified technical skills, and excellent customer assistance. Overall, InoxCast can guarantee a precise, safer, and on-time shipment of your orders.

For more information about InoxCast prototype injection molding, you can message us directly!

Prototype Injection Molding: The Ultimate Guide

Prototype injection molding is vital before mass production process begins.

You need to choose the right injection mold, material, understand design and estimate cost, among other vital aspects.

This guide explores everything you need to know about prototype injection molding.

Take a look:

1.  What Is Prototype Injection Molding?

Prototype injection molding produces mold pieces by injecting molten plastic ingredients through a heat-based injection process.

prototype injecton molding

 It’s one of the best techniques for before any injection molding process begins.

You can use it for high-volume, high-speed, and high-accuracy production, involving various processes for the design feature to be manufactured.

2.  Key Stages In Injection Molding?

 Prototype

When a product is in its early stages, also known as the part/product development stage, the product is known to be infantile.

Here we will need as many questions as possible because it’s critical to have solid input from the manufacturer’s team.

This will always ensure that the design is built in the most efficient method possible, saving money and time.

Generally, at this point, the design is tested to see if it is practical or if there is any need for adjustments to be made before moving forward with the production process.

The number of prototypes produced often ranges from one to five, depending on the product or organization.

They are significantly more expensive due to lower setup and economies of scale costs.

Pre-production

Product is usually in the introduction phase during the pre-production stage after the prototypes have been approved for the design in terms of function, form, fit, and demand.

In most cases, Automatic machines with many pallets are commonly utilized to allow products to be produced constantly without repeated setup.

The setup cost is usually significantly lower per piece because it is divided by the number of parts, making the overall cost per part fairer.

Mass Production

The mass production stage is also known as a continuous flow production.

It mainly occurs when the part has reached the maximum level of possible potential growth and the maturity phase stage.

The mass production will be ready immediately when the product has reached a point where demand for the part is always consistent and in huge quantities.

3.  Prototype Injection Molding Process

This is basically how the injection molding process works, only that we use this for the prototype.

Stage One

Before the production process begins, one of the most crucial things to consider is product design. Typically, various product designs for different functions depending on what you need the part for.

It is essential to select the best design to work on because it will be the one that will achieve the needed target to a satisfactory degree.

To get it properly, you may need a lot of creativity during this process.

With the aid of computer software known as CAD, you may build a product design that is both quick and accurate.

The fundamental rationale for starting with the product design stage is to avoid making mistakes during the manufacturing process.

Stage Two

After the product design stage, the design has been authorized and tested.

The mold will be designed for injection molding manufacture—mold made of hardened steel and material like aluminum, beryllium-copper alloy, and pre-hardened steel is recommended for use.

Mold design also provides an additional option to prevent faults during injection molding.

At this point, the product must be highly manufacturable, efficient, and of excellent quality.

Stage Three

When you’ve finished designing the product and developing the mold, and you’ve received approval for the following stage, you can begin the production process right away.

The process starts with a granular thermoplastic substance fed into a heating barrel through a hopper—the plastic heating to a specified temperature by inserting big screws through the gates and into the mold.

After filling the molds, the screws are always left in place and allow for cooling by applying sufficient pressure for a specific period.

The mold opens as the parts discharge, and the gates will shear off manually or automatically. We will perform the cycle many times to manufacture additional parts in a short amount of time.

4.  Benefits Of Prototype Injection Molding

The following are some of the pros of prototyping injection molding:

• Prototype Injection molding allows a product to be more durable and efficient.
• Prototype injection molding is flexible, as you may readily change the product during the design phase.
• In general, prototype injection molding reduces the overall cost of production.
• Another advantage is that you can do prototype injection molding with a varied range of materials which will depend on the purpose.
• The degree of precision of a prototype injection mold is usually relatively high.
• In addition, prototype injection molding has the advantage of high production output.
• Another advantage of prototype injection molding is the low scrape rate.
• Additionally, prototype injection molding has excellent color control.

5.  Material For Prototype Injection Mold

Aluminum Mold

Aluminum is a rust-resistant, pliable, heat-resistant lightweight metal that can form various shapes. It’s a moldable material that can use in the prototyping injection molding process.

Aluminum mold

Pros

• When compared to steel, it usually has a reduced tooling cost.
• It’s perfect for low-volume runs.
• Easily adjustable and repairable
• Aluminum minimizes the possibility of faults.
• It has the potential to heat up and cool down quickly.

Cons

• Generally unsuitable for large-scale productions.
• It may not be suitable with complicated injection molding designs at times.
• Due to the softness of the metal, it is not appropriate for highly detailed features.

Steel Mold

Steel is well-known for its endurance and good quality; it’s usually a combination of carbon and iron with other elements, which gives it unique features. It is more expensive than aluminum mold.

However, the volume will determine the price. It is well-suited to intricate designs, making it an excellent choice for polytype injection molding.

steel mold

Pro

• It’s excellent for high volume because of its strength.
• Advanced polymers are suited for steel mold.
• It’s best for prototype injection molding with fine details.
• It is quite long-lasting mold.

Cons

• They’re both expensive and difficult to mend.
• It is usually prone to flaws.
• Cooling and heating take a long time.
• It necessitates a larger tooling investment.

6.  Why Is Prototype Injection Molding Important Before Mass Production?

The prototype injection molding is necessary before mass production because of the following reasons;

• It is being able to obtain interactive design feedback early enough to make changes before the procedure begins.
• To eliminate a significant amount of material waste at the end of the project.
• To address any issues the specific design may face with the manufacturers and any other design-related questions.
• To conduct functional testing with the manufacturer in the production material grade.
• To test the form and fit of molded parts before the mass production process.
• It is critical to verify market desires to aid with a pilot launch.
• To lower the financial risk of mass production before it begins
• It will reduce the time it takes to get your final product to market.
• It also aids in the creation of a detailed design.

7.  Which Factors Determine Injection Molding Prototype Cost?

Several factors: usually determine the cost of an injection molding prototype.

The Part Designs

Typically, if your product is complex, you’ll have to get a tough mold that will make prototype injection molding pricier.

This is because it requires more tooling than simple parts, which are easier to handle and less expensive.

EDM can be used frequently for the undercut features for complex parts, which are often costly. Larger sections typically require more material, which raises the cost.

Part Material To Be Used

Another aspect that influences the cost of injection molding prototypes is the material used.

When choosing a material, you must consider durability, color, material availability, grade, and molding temperatures, all of which are costly when taken into account.

When using materials that can withstand higher temperatures, the cost will be higher because they are more expensive than those that can withstand lower temperatures.

As a result, it will all rely on the type of material you choose to employ.

Mold Material Used.

There are a variety of steels to be used for injection molding prototypes, but certain varieties you will require for specific purposes.

The greater temperature of thermoplastics entails using steel with a higher hardness, which is more expensive.

Each mold material has a different lifespan based on its durability and cycle duration, especially for steel molds.

While aluminum is typically less expensive, it is ideal for molds with shorter production runs.

Cavities And Volume

Whenever you need additional cavities to make a part, the press time will usually be longer.

There is frequently a limit to how quickly parts may be produced with lengthier press times, resulting in higher costs.

Many cavities will be required to generate a higher volume of parts, resulting in higher production costs.

Location Of The Mold Manufacturer

The area of a molding manufacturer has a significant impact on the cost, which includes the cost of handling and shipping the mold to the processing location.

For example, the average wage varies by the province in certain nations, which you must consider. Choosing a manufacturer overseas will raise the price, whereas the cost will be low locally.

Mold Finish

Another aspect that influences the price of a prototype injection mold is its mold finishing. When it comes to finishing, you usually have a lot of options.

If you choose a more advanced choice, such as very smooth finishing, you will pay a higher price than if you choose one of the standard rough once finishing alternatives.

It’s critical to learn more about the mold finish possibilities and select the one you can afford.

Cooling System

Typically, several solutions are available for prototype injection molding, all of which impact manufacturing costs.

If you use a more modern cooling system, it increases the cost and lengthens the cycle time.

Unlike traditional cooling methods, which are less expensive, part cooling may not achieve the needed consistency.

If you want the best cooling system for your parts, one of good quality and reduces part waste, the cost will be more.

8.  What Is Rapid Prototyping Injection Molding?

Rapid injection molding prototyping is a technique for fast producing parts to bridge the gap between prototype and mass production.

It is also a cost-effective technique.

Rapid prototype injection molding may be constructed of aluminum or steel, and you can choose between the two.

On the other hand, steel is the most commonly utilized material since it produces more than twice as many pieces as aluminum.

9.  3D Printed Prototypes Vs. Injection Molded Prototypes?

3D Printed Prototype

The following are some of the applications for 3D printed prototypes:

• Developing designs that are usually still in the concept stage
• Low volume manufacturing runs of 100 pieces or less
• One to the fifteen-day turnaround times for 3D printing prototypes
• Mainly deal with little plastic parts

3D printed prototype

Injection Molded Prototypes

The best applications for injection molding prototypes are:

• The completed designs that require actual testing
• The prototype with more than 100 parts
• It has a two-to-five-week turnaround time
• Complex parts of any sizes

injection molded prototype

10.  Benefits Of Rapid Tooling For Prototype Injection Molding?

Rapid tooling for prototype injection molding offers important benefits, including:

• Rapid tooling for prototype injection molding allows for complete customization of parts, an advantage.
• The time between development and manufacturing is typically relatively short, making it a more efficient process.
• Because it is an accurate tooling and quick production, it generally contributes to production efficiency and market introduction.
• Rapid tooling for prototype injection molding allows for fixing and design testing.

This allows for the accurate creation of new tooling that will apply design modifications and enhancements.

• The quick tooling process is very cost-effective for all customers.
• It also can give unique opportunities for creativity by removing the constraints that the older ones once had.
• Another advantage of prototype injection molding quick tooling is that it decreases parts wastage by reducing material loss, which every manufacturer desires.

More Resources:

Metal Injection Molding

Die Casting

Plastic Injection Molding

Thermoplastic Injection Molding

For all your prototype injection molding, contact us now.