When starting to produce a new product, it’s important to decide on the type of process you will use for the manufacturing process.  While injection molding is a very cost-effective process, the initial startup cost of the mold is often a barrier of entry.

Injection molding is a manufacturing process that is very efficient for producing parts in large volume.  It is typically used in the mass production process where the same part is being created in the thousands or even millions.

Upfront costs tend to be very high due to the design, testing, and tooling requirements.  If you are going to produce parts in high volumes, you want to make sure you get the design correct the first time. So, what are the costs associated with producing an injection mold?

  • Choice of Resin

One of the biggest factors that effect the price of the plastic injection molding process is the type of plastic resin used in manufacturing.  The choice of material will change the price based on color, compounding, and additives.  The most abrasive or corrosive the material, the most expensive the mold.

  • Complexity

The more intricate the component, the more difficult it is to design the manufacturing process.  Part complexity, tolerances, number of undercuts as well as surface finish all effect the cost.

  • Size

The size of the component also drives the price.  Larger parts require larger, more expensive molds, as well as more material to manufacture.  Larger molds also take longer to make, which increases the costs.

  • Mold Material

The material the mold is made from significantly impacts the price.  Short production molds are usually made from less expensive materials such as aluminum.  Long production molds require molds made from more durable and expensive materials like steel that will retain their features across several years.

  • Cavities

The higher the number of cavities – the higher the production costs.  Experienced mold designers can maximize cavitations to enhance productivity and lower costs even for the most intricate parts and components.

  • Mold Base

The base of the mold is the case used for holding all the components, inserts and cavities of the mold.  The price of the mold base depends on the type of steel and the size of the mold.

At Performance Plastics, we know how important it is to make the correct decisions when designing a mold.  We have a team of process experts who work with our clients to design and assist in the mold process. We focus on the total cost of ownership of a mold, production capacity, longevity, functionality, as well as initial capital expense.

To learn more about how Performance Plastics can help you with your molding process, contact Rich Reed, Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com.

Performance Plastics is pleased to announce the addition of our new Senior Customer Service Coordinator – Lori Bragg. Lori joins Performance Plastics with over 30 years’ experience, B.A. in Communications, and working with industry leading companies in Cincinnati, Ohio.

“Lori brings a wealth of experience in B2B manufacturing, inside sales, ERP processes, and customer service to our company” said Rich Reed, Vice President of Sales and Marketing, “The addition of Lori as a Senior Customer Service Coordinator is a representative of our continued commitment to provide our customers with the excellent customer service they have come to expect from PPL.  We are excited to have Lori join us and look forward to continued growth.”

Lori stated, “I look forward to helping Performance Plastics continue to meet our customers’ expectations by providing the highest level of service.”

Performance Plastics Ltd is a custom injection-molder of high-performance polymers for mission critical markets including Aerospace/Defense, Medical, and Precision Industrial.

 

At Performance Plastics, we hold the quality of our products to the highest standards. We know that quality is critical for our customers, so we go above and beyond to make sure our customers products are no less than ideal.

Manufacturing quality products is key to maintaining long term relationships with our customers. We take the time after injection molding a product to test the quality and to quantify compliance standards. This extra time assures that we are meeting all the specifications of our customers’ products.  To this end, we maintain SEMI F57 compliance for our customers PFA (Perfluoroalkoxy) and PTFE (polytetrafluoroethylene) injection molded products.

SEMI F57 compliance is a specification for polymer materials and components used in ultrapure water and liquid chemical distribution systems. The SEMI F57 standard requires fluid-component manufacturers to follow best practices in material science and not contaminate UHP processes with extractable ions, metallics or total organic carbon (TOC). The standard also covers surface roughness, particle contribution, metallic contamination, and reliability testing.

SEMI F57 Standards ensure compliance as they identify permissible limits for seven different aqueous leachable anions: bromide, chloride, fluoride, nitrate, nitrite, phosphate and sulfate.  Additionally, the standards measure for elevated levels of total organic carbon (TOC) which can have negative effect on silicon oxidation.

In order to ensure that we maintain SEMI F57 compliance, we have added new, additional quality testing steps. The steps occur during the molding, cleaning, drying and packaging processes. These quality tests are crucial – they certify that each product injection molded by Performance Plastics follows the SEMI F57 standards and will not contaminate ultrapure water and liquid chemical distribution systems.

For more information on how Performance Plastics can help your injection molded PFA or PTFE product achieve SEMI F57 compliance, contact Rich Reed our Vice President of Sales and Marketing, at (513) 321-8404 or RReed@performanceplastics.com.