INJECTION MOLDING
Experienced Capability.
Exceptional Craftsmanship.
Mastery in every mold.
Precision Plastics for Mission Critical Parts
At Aprios, we specialize in precision plastics for mission-critical parts, focusing on creating components where lives may be on the line, such as medical devices and safety equipment. We understand the gravity of plastic manufacturing for applications where failure is not an option, ensuring our plastic molding products meet the standards of accuracy, reliability, and performance. Our quality control processes and plastic molding techniques ensure that every part we produce is flawless, making us the ideal choice for high-stakes plastic manufacturing that requires dependability, rather than commodities like plastic spoons.
Our overmolding process allows us to combine multiple materials into a single component, enhancing functionality and performance. This process is ideal for creating ergonomic designs and improving the durability of parts. We use cutting-edge technology to ensure a seamless bond between materials, resulting in superior end products.
Insert molding integrates metal or plastic inserts into the molded parts during the injection process. This technique enhances the strength and functionality of components, making it perfect for complex assemblies. Our expertise in insert molding allows us to produce parts with embedded reinforcements, electrical components, or threaded inserts with precision.
We offer specialized medical molding services to produce high-precision, sterile components for the healthcare industry. Our Class 8 Clean Room ensures that all medical parts are manufactured in a controlled, contamination-free environment. This guarantees the highest standards of cleanliness and compliance with medical regulations.
Micro injection molding is a technique for producing tiny and precise components using minimal resin volumes in the injection procedure. Our expertise in micro injection molding allows us to create intricate parts with high accuracy, perfect for industries such as medical devices, electronics, and automotive components.
Features & Ancillary Services
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Prototypes to Production at Scale
Our injection molding services cater to a wide range of needs, from small quantity prototypes to full-scale production. Whether you need a few test pieces or millions of units, we have the capability to meet your demands efficiently. Our flexible production processes ensure that you receive high-quality parts on time, every time.
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Tool Transfer
We have a defined project management and quality assurance process for intaking tools from other manufacturers. Our team can repair and modify existing tools to get your production back on track quickly. With our expertise, we ensure a smooth transition and minimal disruption to your manufacturing process.
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Post-Processing and Assembly
Beyond molding, we provide comprehensive post-processing and assembly services. Our secondary operations include machining, bonding, and finishing, ensuring that your parts are ready for immediate use. We can also offer assembly and packaging in our Class 8 Clean Room, maintaining the highest standards of cleanliness and quality.
Design for Manufacturing (DFM) for Injection Molding
Design for Manufacturing (DFM) for injection molding involves optimizing the design of parts to improve manufacturability, reduce costs, and enhance quality. By integrating DFM principles, we ensure your designs are ready for efficient and effective injection molding production.
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Key DFM Considerations:
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Wall Thickness
Maintain uniform wall thickness to prevent defects such as warping and sink marks. For example, designing a plastic enclosure with consistent wall thickness ensures even cooling and material flow.
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Draft Angles
Incorporate appropriate draft angles (typically 1-2 degrees) on vertical surfaces to facilitate easy ejection from the mold. For instance, adding a slight taper to the sides of a plastic cup makes it easier to remove from the mold.
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Ribs and Gussets
Use ribs and gussets to add strength without increasing wall thickness. For example, adding ribs to a plastic panel increases rigidity while keeping the part lightweight.
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Undercuts
Minimize or eliminate undercuts to simplify mold design and reduce tooling costs. For instance, redesigning a part to avoid internal undercuts can eliminate the need for side actions in the mold.
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Gate Placement
Optimize gate locations to ensure uniform filling and minimize defects. For example, placing the gate at the thickest section of a part helps ensure proper material flow and reduces the risk of sink marks.
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Material Selection
Choose materials that are suitable for injection molding and meet your product's performance requirements. For instance, selecting a high-impact resin for a component that will experience significant wear and tear.
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Mold Flow Analysis
Conduct mold flow analysis to predict and address potential issues such as air traps, weld lines, or hotspots. For example, simulating the injection process for a complex part can help optimize gate locations and cooling channels.
By incorporating these considerations into your design, we ensure a more efficient injection molding process, leading to high-quality, cost-effective parts.
Why Trust Aprios with your Injection Molding Needs
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Quality Assurance and Compliance
We adhere to stringent quality assurance protocols and comply with industry standards to ensure the reliability of every part we produce. Our comprehensive testing and inspection processes guarantee that each component meets your exact specifications. For more information, please visit our Quality page. This commitment to quality reduces the risk of defects and enhances the overall performance of your products.
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Design for Manufacturing (DFM)
Our Design for Manufacturing (DFM) services help you optimize your designs for efficient and cost-effective production. By collaborating early in the design process, we identify potential issues and suggest improvements to enhance manufacturability. This proactive approach reduces time-to-market, lowers production costs, and ensures that your products are designed with manufacturing efficiency in mind.
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Quick-Turn Tooling
We understand the importance of speed in bringing new products to market. Our quick-turn tooling services enable us to deliver parts within a month after placing an order. This rapid turnaround time allows you to accelerate your product development cycles and respond swiftly to market demands, giving you a competitive edge.
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Partnership and Support
We view our clients as partners and are dedicated to supporting your success from concept to completion. Our experienced team is available to assist with design, prototyping, production, and post-production services. This end-to-end support ensures a smooth and successful project execution, allowing you to focus on your core business objectives.
Frequently Asked Questions
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What types of materials can you use for injection molding?
We can work with a wide range of thermoplastic materials, including ABS, polycarbonate, polyethylene, polypropylene, and more. We select materials based on your specific application requirements, such as strength, flexibility, and temperature resistance. We do not work with PVC or Teflon.
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What are the benefits of overmolding and insert molding?
The overmolding process enhances the functionality and aesthetics of a product by combining different materials, such as a rigid plastic with a soft-touch surface. Insert molding integrates metal or plastic inserts into the molded parts, increasing strength and functionality, and is ideal for creating complex assemblies.
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Can you handle small and large production runs?
Yes, we have the capability to manage both small quantity prototypes and large-scale production runs. Our flexible manufacturing processes ensure high-quality production regardless of the order size.
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What are the build size limitations for your injection molding services?
We can handle parts with surface areas up to 156 square inches in the direction of the mold clamp. Specific dimensions like 10x15 or 12x13, and shot weights up to 61 ounces (3.8 pounds), are within our capacity.
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How do you ensure the quality of injection molded parts?
We adhere to strict quality control processes, including comprehensive testing and inspection at various stages of production. Our commitment to quality ensures that each part meets your exact specifications and industry standards.