An Injection Molding Company Focused on Customer Satisfaction
Since 1988, companies around the Southeast and Mid-Atlantic states have turned to us for custom plastic parts because we are a customer-focused company who refuses to cut corners. While many of our plastics are manufactured through thermoforming, we also use injection molding in cases where it’s beneficial to the customer or is necessary to the design.
Because injection molding requires more intensive design and development processes as well as more expensive materials to fabricate the tooling and mold, we know our customers may have hesitation about using this method to produce their plastics. However, we understand how important innovation is to continued quality, which is why we have invested heavily in the equipment, technology, and experience to improve injection molding at our North Carolina facility including presses ranging between 100 and 530 tons. Working with the top tooling manufacturers in the United States and overseas, our injection molding company can deliver more affordable tooling. This has allowed us to lower prices and reduce lead times without sacrificing quality and accuracy.
The Injection Molding Process
The process begins by sitting down with our plastic engineering team to discuss the specs of the project – this includes what the plastic is, what it will be used for, quantity, and other information. Using this, we can determine if thermoforming or injection molding is the best method of production.
With a plan in place, our design team will create highly detailed 3d modeling that we can use to create a prototype. The prototype allows us to ensure accuracy to the design and to your original needs, giving us the opportunity to make any tweaks or adjustments. Once the prototype is approved, our injection molding company then commissions the tooling. Due to the high pressures required in the molding process, the tooling must be a double-sided design, manufactured from steel, aluminum or a beryllium-copper alloy which accounts for the higher cost of tooling compared to thermoforming.
In injection molding, we have a wide variety of materials available to use in the form of thermoplastic pellets. The pellets are melted to a liquid, any additives are included to the liquid, then our powerful injectors force the plastic into the custom tool to ensure every necessary detail is captured, including angles, thicknesses, and curves.
After proper cooling, the parts are ejected from the mold, in many cases, ready to be used as the finished product. In some projects, further processing is required and injection molded parts are often painted, silk screened or coated with specialty coatings for aesthetic or functional purposes.
The Advantages of Injection Molding
We often select injection molding as our method of production because it has several advantages that make it better for specific projects.
High Volume Orders
While the upfront tooling cost is more expensive, once it’s made, we can use it forever, making this a better manufacturing choice for high volume orders or those that require repeat fulfillments.
Complex or Advanced Component Designs
Our injection molding company creates two sided molds to create a complete shape. This allows us to achieve varying degrees of thickness, while the high pressure means we can get more intricate details like sharp corners and angles.
For things like dials, buttons, and small parts and components, injection molding achieves the consistency and accuracy necessary. Whether you’ve shaped 10 pieces or 10,000, they will all look and perform exactly the same.
Contact Our Injection Molding Company for Your Next Project
Searching for an injection molding company in the Southeast or Mid-Atlantic area? We can help! Our North Carolina thermoforming and injection molding company offers customers the expertise of staffed engineers, experienced work crews, and multiple value-added services to improve your supply chain practices. From concept to delivery, API is your answer for custom plastic products manufactured in North Carolina, South Carolina, Pennsylvania, Maryland, Tennessee, Georgia and Virginia.
To get started on your vacuum forming project, please contact us today by calling 919-404-2080 or filling out our form below to discuss your custom plastic manufacturing needs.