Plastic Injection Molding Service Provider

Injection Molding

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All-Around Injection Molding Company for
Plastic Products

At FOW Mould , we offer a full range of injection molding services. Do you need a product design or a prototype produced to test for viability? We have what it takes to meet your needs.

You can count on us to deliver high-quality molds made to precision within turn-around times as short as 10 days. Are deadlines breathing down your neck? No need to worry. We are well-equipped with enough injection machines to fast-track your orders. 

FOW Mould is also experienced in handling hundreds of resins. We offer a wide material selection and source unique alternatives for our clients on request.

Advantages of FOW Mould's Injection Molding

FOW Mould has been providing injection molding services to businesses for over 40 years. We combine this wealth of experience with the latest technology in the industry to offer you dynamic and cost-effective injection molding solutions. Further, we have a diverse team of designers and engineers that specialize in different sectors. This enables us to cater to the automotive, furniture, baby product, and warehousing industries among many others with great expertise.

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    Rapid Prototyping

    Quick production of prototypes helps to shorten the time spent in developing part designs. It also gives you fast feedback on their viability. This is why we have invested in top-of-the-line 3D printers and CNC machines that enable us to deliver your prototypes within the shortest timelines possible.

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    Scalability

    We have the capacity to produce over 600 set molds in a year. Additionally, FOW Mould has cultivated a vetted network of partners that work with us and supplement our production scale. As such, no order is too big for us. We also accommodate low-volume orders because we understand that our clients serve different market sizes.

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    Outstanding Quality

    We handle various materials sourced only from vetted suppliers. Each of these procedures is performed under the supervision of experts who are guided by our strict quality policies. Parts and prototypes are only dispatched to clients if they meet our quality management standards.

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    High Precision

    Fortunately, as our client, you will never have to worry about precision. Our CNC machines have a tolerance of about +/-0.02mm while our high-speed CNC models have a tolerance of +/-0.002mm. This is in line with the recommended international industry standards.

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    Cost-Effectiveness

    One injection mold can be used to make thousands of parts. Working with us would also give you access to a full array of injection molding services at affordable rates as opposed to engaging multiple service providers. Our precision and short turnaround times further help to keep production costs low.

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    High Efficiency

    Based on your product quantity and delivery date, FOW is able to deploy multiple injection machines to meet your demands. Our capabilities in injection molding ensures that your contract manufacturing for plastic parts can shorten your time to the market and meet your clients’ expectations.

What Is Injection Molding

bucket injection molding process

Injection molding is a production method used to manufacture plastic parts by injecting molten plastic into a preformed metal mold. The molten plastic is injected at a predetermined temperature and pressure and left to cool. When it has solidified and adapted the shape of the mold, it is ejected as a formed part.

Types of Injection Molding

The typical injection molding process can be used to produce a wide variety of parts. However, there are enhanced types of injection molding that can be used to add design features to a part. 

Insert Molding

Insert molding involves placing an insert or substrate into the mold cavity before injecting it with molten plastic. The insert can be made of metal or any other material that can withstand the temperature and pressure used in injection molding.

When the molten plastic is injected into the cavity of the mold, it settles onto and around the substrate and bonds with it. The part formed would, therefore, comprise a fusion of plastic and metal. This type of injection molding is used to:

Increase the weight of the part

Achieve threads on a plastic part

Add cosmetic or functional value

Improve the IP rating of the part

Pros:

Bonding the parts during injection molding yields neater structures than assembling them later when they are already formed

It is cost-effective

It is faster than separate assembly

Cons:

It increases cycle times

An insert slightly increases the odds of defective outcomes

Overmolding

Overmolding is done in two stages. It begins with the part being formed through the typical injection molding process. Once it is complete and has cooled, the core of the mold is placed over it one more time. Another layer of molten plastic is injected into the cavity. Depending on the intended design, the second layer of injected plastic may cover the whole or only specific areas of the part that has been returned into the mold.

The second layer of molten plastic injected during overmolding can be of a different grade and color from the one originally used to make the part. However, the materials need to be chosen carefully to ensure that they can bond well together. Different thermoplastics also require to be injected at specific temperatures and pressure from others. These parameters would, therefore, have to be adjusted during the second injection molding procedure.

This type of plastic injection molding is used to:

Strengthen the structure of the original part

Add flexibility to rigid areas

Add functional features like grip

Blend colors

Encase one plastic part in another without using adhesives or connectors

Pros:

It makes it easy to combine different materials

It is faster, more convenient, and effective than manual two-step assembly

Overmolding offers more seamless connectivity when encasing one part in another

Cons:

It increases cycle times

Multiple colors may not always blend with consistency

The Injection Molding Process

First, the part is designed in detail including precise dimensions and other structural specifications. Prototypes are then made to provide a more tangible sample of the part. The goal here is to examine the structure and test it for stability, functionality, and aesthetics. If there are any errors or modifications to be made to the design, the prototype would be reconfigured and printed for a second evaluation. This is done until the design is perfected.

Once the part design is complete and approved, mold-making which is also known as tooling can begin. A mold is a structure made of steel or aluminum. It has two parts: a core and a cavity; the core is solid but the cavity is hollow. Both are designed to match every detail of the part design. Their dimensions, curves/corners, rifts, or ridges are all made in likeness to the part that is to be manufactured. It takes high precision to make the perfect mold design and the process can take several tries.

When the mold is made, it is connected to an injection machine system, and the injection molding process proceeds as below:

A hopper is loaded with thermoplastic material which is gradually loaded into a barrel and melted.

Hydraulic or electric presses close the mold by pressing the core onto the cavity with great force.

The nozzle of the injection machine injects the molten plastic into the mold cavity at a predetermined high pressure and temperature.

After injection, the molten plastic cools and takes in the shape of the mold.

When it achieves the right cooling temperature and solid form, the mold opens along the injection mold parting line and ejector pins carefully push out the formed part.

Injection Molding Material Options

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Our team of staff is experienced and skilled at handling all kinds of injection molding materials. You are welcome to choose any of the polymers on our list of options which includes:

  • PP
  • ABS
  • PC
  • PE
  • PA6
  • Nylon
  • POM
  • PVC
  • PS
  • PMMA
  • PLA

Additionally, we have established business relationships with verified suppliers of a diverse range of alternative resins. We would be glad to source them for you upon request.

Finish Options of Injection Molding

We offer different premium quality finishes to accommodate a variety of designs that our clients may present to us. They include:

  • Mold Texturing
  • Custom color-matching
  • Threaded inserts
  • Pad printing
  • Laser engraving
  • Basic assembly
  • standard finish
  • SPI finish

Some finishes are performed during the injection molding process while others are performed afterward. Our plastic molding injection factory is fitted with top-standard technology to handle both kinds.

Our Plastic Molding Plastic Molding Options Help You Save on Costs

FOW Mould services are tailored to ensure that we are a one-stop-shop for all your injection molding needs. We work with you right from designing the part and prototyping to creating the mold and forming the part. You no longer have to incur exorbitant costs paying individual firms for each procedure. Additionally, we capitalize on our massive economies of scale to offer you affordable prices while maintaining high standards of quality. 

Further, our molds are made of premium steel and only high-grade resins are used in our injection molding processes. This makes our products durable and reduces your long-term costs.

Applications of Injection Molding

Medicine

The production of medical devices is complex and strictly controlled by regulatory authorities. Every proposed design for a medical device, therefore, has to be rigorously tested for functionality and safety. Often, multiple modifications also have to be made before the part is approved for production.  

Injection molding is used to make accurate prototypes and preliminary samples of medical devices before they are approved. It is fast, affordable, and allows for modifications to be made over multiple tries until the design is perfected. We have in-house experts that are well-versed with medical device stipulations. Reach out to us and let us help you make your medical device the best it can be.

Bucket

For bucket molds, the most important factor to consider is the consistency of wall thickness because uneven wall thickness will result in molding injection failure after a certain period. This requires high accuracy tools throughout the manufacturing. FOW Mould’s tooling machines are of high precision which ensures the accuracy of the molds, thus lengthen the mold life.

Other than wall thickness, the cooling system also plays a vital role in the upcoming molding injection period. The cooling system must be designed based on the bucket specifically. Improper cooling water lines might affect the efficiency of the whole injection molding process. With FOW’s 10 years experience in bucket mold, we are able to avoid mistakes and offer you the most reliable mold-making service.

Warehouse & Storage

In Warehouse & Storage, crates and pallets are widely used. Molds for crates and pallets are relatively large, so the manufacturing cost might be higher. At FOW, when designing molds for these products, we conduct a MoldFlow analysis to predict any possible failures, which guarantees in the success of crate mould design and manufacturing. Over the years, FOW has gained rich experience in the design and manufacturing of moulds of crates and pallets, they now:

  • Lighter in weight & smaller in size
  • More compact in structure
  • Have better usage for resins
  • Reduce cycle time

Baby Product

Pediatric experts recommend that baby toys, furniture, and other equipment be made of smooth, non-corrosive, and lightweight materials. Plastic fits this bill perfectly and this is why it is used for most baby products. They are produced using injection molding because it makes it possible to reiterate one design countless times. Moreover, injection molding processes like overmolding make it possible for baby products to be made colorful and seamless without screws and other risky connectors. 

We have a vast catalog of eye-catching designs and color combinations that would have babies cooing for your products. Our resin options can also be curated to achieve the highest standard of baby-friendly products.

Furniture

Plastic furnitures combine the features of comfort, cost-effectiveness and style. When designing a chair, for example, weight load is the first priority because this determines whether this is a safe and comfortable chair. To achieve this, our product designers must work closely with our clients to understand the needs of the target market and pass important information onto our mold designers. Besides weight load of the chair, we also need to consider whether each chair is stackable. This requires our product designers and mold designers to work together to develop a safe and comfortable that’s stackable.

Automobile

FOW Mould also has rich experience in automobile parts. For automobile molds, accuracy is the one thing that needs extra attention. All of our mold parts are processed by high precision machines, thus our injection molded parts are within a specific tolerance rate as our clients require.

Before proceeding to the mold-making period, our engineers run analysis on the product design and mold design, preventing any possible mistakes.

Home Appliance

Most home appliances are injection molded nowadays. To ensure a product’s quality, we need to put more attention to product design and mold trial in the final step. Product design is important because it has direct influence on product performance and the product life. Our product designers work closely with our client to confirm each functionality and detail, reducing the possibility of failures.

To further ensure product quality, we run mold trials for each project. We calibrate the mold until all the demands have been met.