An Injection Molding Company Focused on Customer Satisfaction
If you’re in need of custom plastic parts, products, and components that are durable, long-lasting, and accurate to your design, finding the right plastic injection molding company is essential to getting the results you want. Since 1988, we have partnered with companies across all types of industries assisting in design and engineering in addition to the manufacture of high-quality plastics to ensure optimal results.
While thermoforming is our primary manufacturing method, we rely on plastic injection molding in situations where it’s beneficial to the customer or essential to the design. With our state-of-the-art presses that offer up to 610 tons of pressure and connections with the leading tooling manufacturers both domestically and overseas, we are able to offer shorter lead times and lower per-unit pricing without compromising quality, accuracy, or service.
What Is Plastic Injection Molding?
Injection molding is a method of plastic manufacturing that is primarily used in large-volume production. Thermoplastic material is melted to a liquid state and, using a highly pressurized injection tool, the plastic is injected into a custom mold. The pressure is necessary to ensure the thermoplastic coats and fills the entire mold, capturing all the essential details, corners, and angles while eliminating any risk of air bubbles, gaps, or other flaws in the finished product. Once cool, the finished pieces are ejected from the mold.
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 of 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
One of the frequently asked questions about injection molding is what advantages there are in using this method of production for specific projects.
Let’s take a closer look at some of the injection molding advantages.
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 and create more complicated pieces. Medical injection molding is common for these needs.
For things like dials, buttons, and small parts and components, automotive 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 injection molding project, please contact us today by calling 919-404-2080 or filling out our form below to discuss your custom plastic manufacturing needs.