Protolabs Accelerates Plastic Part Production with Rapid Molding

For manufacturers struggling with lengthy production cycles and high costs for plastic components, a transformative solution has emerged. Imagine obtaining custom plastic parts within days—or even a single day—at lower costs and with superior quality. This is now a reality, thanks to advancements in injection molding technology.

Injection molding has long been a cornerstone of efficient and cost-effective plastic part manufacturing, widely adopted in industries such as medical devices, consumer goods, and automotive. The process involves injecting molten plastic resin into a metal mold cavity, where it cools and solidifies into the desired shape. This method enables mass production while minimizing material waste and reducing per-unit costs. Now, innovative solutions are making the process even faster and more flexible, accelerating the journey from concept to finished product.

Leading providers of rapid injection molding services, such as Protolabs, offer unparalleled benefits:

• Unmatched Speed: Custom prototypes and production-ready parts can be delivered in as little as one day, eliminating prolonged wait times and keeping projects on track.
• Cost Efficiency: Aluminum molds and optimized production workflows significantly reduce tooling and per-part expenses.
• Material Diversity: With access to over 200 thermoplastic resins, manufacturers can select the ideal material for any application.

Injection molding is versatile, catering to a wide range of needs:

• Low-Volume Production: Quickly adapt to market demands with flexible manufacturing scales.
• Bridge Tooling: Conduct small-batch trials before committing to full-scale production molds.
• Pilot Testing: Validate designs and mitigate risks with limited runs prior to mass production.
• Functional Prototyping: Accelerate design iterations by rapidly producing and testing prototypes.

Comprehensive design guidelines are available to ensure manufacturability, aesthetic refinement, and reduced production time. Adhering to these recommendations helps avoid design flaws, streamline processes, and lower costs.

Standard tolerances are typically maintained at ±0.003 in (0.08 mm) for machining, with resin-specific tolerances that may exceed but not fall below ±0.002 in/in (0.002 mm/mm).

Over 100 thermoplastic and thermoset materials are available, including:

• ABS and ABS/PC blends
• Acetal and Delrin (acetal homopolymer)
• ETPU, HDPE, LDPE, and LLDPE
• Nylon, PBT, and PC/PBT
• High-performance options like PEEK, PEI, and PSU
• Common resins such as polycarbonate, polypropylene, and TPU

Draft angle requirements vary by finish type. Industry-standard Mold-Tech textures are also available.

Optional services include:

• Design for Manufacturability (DFM) feedback
• Scientific molding process reports
• In-process CMM inspection and machine monitoring
• First Article Inspection (FAI) with GD&T capability reports
• Post-molding operations like texture application, threading, printing, and assembly

The thermoplastic injection molding process employs aluminum molds without heating or cooling channels, resulting in slightly longer cycle times. As part of scientific molding, parameters such as fill speed, pack pressure, and hold time are independently optimized and monitored. Automated in-line CMM systems verify dimensional accuracy, with detailed process capability studies and FAI reports generated for quality assurance.

Resin pellets are fed into a barrel, melted, and injected into the mold's runner system. The molten material flows through gates into cavities, where parts form. Ejector pins assist in part removal, after which components are packaged and shipped.