Plastic Injection Molding

50 to 100,000+ parts

Molds and Moldings

3-30 days

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Plastic Injection Molding

Our injection molding tools allow us to create parts from simple to complex with short lead times. Rapid turn-around tooling is our specialty. We provide injection molding tools in 7075 aluminum, P20, H13 and NAK80 tool steels. We also make finished parts in volumes from one-offs to thousands of pieces in batch production. Tooling can also be 3D metal printed with conformal cooling and heating channels for demanding applications.

50 to 1000+ Injection Molded Parts

For prototype molds we typically use pre-hardened P20 tool steel or 7075 aluminum to make the core, cavity and ejector plates which are assembled into a Master Unit Die (MUD) base. We can add custom cooling circuits, hot tips, and other refinements to aid with the production of technical resins or complex geometries. For polished or high-gloss parts, we use NAK-80, a polishing grade of stainless steel. Low volume production of injection molded parts is ideal for 50 pcs. up to one thousand parts of varying complexity. This option offers medium tooling and part price.

1000 to 100,000+ Injection Molded Parts

For pilot production molds we typically use pre-hardened P20 tool steel or NAK-80 stainless tool steel to make a complete mold, which is, in effect, a full production tool without full hardness. To reduce lead times and costs, we do not offer these molds for export; all of our pilot production or ‘bridge tooling’ molds are built to local standards. Medium volume injection molding dies are ideal for thousands to hundreds-of-thousands of parts of varying complexity. This option incurs a higher tooling cost but a much lower part cost.

100,000+ Injection Molded Parts

These are full production injection mold tools that will be exported outside China for our customers to run in their own facilities or at a local molders. (Only available for export to USA currently.) Molds are to full USA / western standards. Typically up to 8 cavity molds, maximum injection mold press size 500 tons, steel type P20, H13, NAK 80. Open and shut, multi-slide, unscrewing etc. are all available.

Tolerance Guide Sheet

Unless otherwise specified, we comply with the DIN 16742 standard tolerances for plastic injection moldings. We need to know your requirements in advance so that we can manage key features in the tooling and molding process. As a general rule, high-precision features can only be achieved on select areas of the tool depending on the application. A guideline for tolerances can be downloaded here: Star Prototype: Plastic Injection Molding Tolerance Guide

Materials

At Star Prototype we can use virtually any resin that you require for plastic injection molding. We can purchase special materials from the local market, or we can import them. Please check out our list of thermoforming resins to get an overview of the standard materials that we use.

Color Consistency

Color consistency for injection molded parts poses a challenge. This becomes apparent when mating parts in any assembly where colors need to match perfectly. For more information about the challenge of color consistency read our white paper here:“Color consistency“.

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Fast Delivery

Our OMOM® approach allows us to eliminate unnecessary communication and queue time, but also allows us to create very complex tooling quickly.  Time is money.

Mold Modification

New designs commonly require tool modifications. At STAR we already factor in a number of design revision related tool modifications.  Happy to help.

Production Finishes

Although our OMOM tooling is for prototype and low-volume runs, we aim to give you production quality finishes.  If you design to industry standards, we can do it.

Competitive Price

We are able to combine the cost savings of Asia with the expertise of our international team of managers and engineers to provide best-in-class performance at a competitive price.

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