Plastic Injection Molding

World-Class Injection Molding Services

Small and large scale injection molding Request an injection molding quote today.

Injection Molding

Star Rapid is a world-class provider of advanced injection molding services. We offer a complete manufacturing solution that covers every aspect of positive material identification, tool making, part fabrication, finishing, and final inspection. Our international team of manufacturing experts is committed to providing you with the highest level of professional support for injection molding services of any size or complexity. We offer three tiers of injection molding services to ensure that you get precisely the solution that’s best for your intended volume, production time and budget.

Services

OEM ODM Injection Molding Services

We are able to accurately machine plastic parts according to the size, complexity and quantity of parts required. We offer prototype and mass production services to ensure the accuracy of each design. All injection moulding orders benefit from a free design consultation to ensure your needs are met. Once pricing is confirmed, we provide a Design for Manufacturing (DFM) analysis of your product.

Injection Mold Tooling

Injection molds are crucial for mass-producing precise plastic molded parts. Made primarily from steel or aluminum, their creation involves intricate design, precise machining, and assembly.

Plastic injection molding is a technique where molten thermplastic is forced into molds, solidifying into parts. Enabling efficient, and large-scale production with consistent quality.

Overmolding

Overmolding combines different plastic materials by molding one over another, enhancing functionality, aesthetics, and grip, while reducing assembly time and costs.

Insert Molding

Insert molding encases a pre-set insert with plastic, merging metal and plastic, enhancing strength, simplifying assembly, and ensuring precision integration.

What is Mold Design For Manufacturability (DFM) Report

Mold Design for Manufacturability (DFM) Report

Design for Manufacturability (DFM) report serves as a vital conduit between product developers and mold manufacturers, widely acknowledged for its efficacy across diverse manufacturing sectors. A meticulously crafted DFM report lays the foundation for success in mold-making projects, enabling proactive risk mitigation for mold makers. Below is a succinct overview:

Resin Selection

The DFM report functions as a linchpin between product developers and mold manufacturers, recognized for its role in enhancing operational efficiency across various industrial domains. A comprehensive DFM report is paramount for the success of mold-making endeavors, affording mold makers the foresight necessary to preempt potential challenges in the manufacturing process. Presented here is a concise synopsis:

Draft Angle Optimization

Draft angles are indispensable for facilitating part ejection from mold cavities, albeit necessitating judicious consideration to minimize any perceptible deviations from the original product design. Collaboration between mold manufacturers and designers is imperative in addressing this aspect.

Thickness Considerations

Rib thickness is ideally maintained at approximately 60% of the wall thickness to ensure uniformity and mitigate the risk of thin wall sections.

Gate Selection and Placement

The strategic selection and placement of gates are pivotal, particularly for parts demanding stringent surface finishes. The choice of gating methodology not only dictates manufacturing processes but also influences mass production costs.

Mechanical Configuration and Parting Lines

A succinct exposition on the mechanical configuration employed in mold design, encompassing elements such as sliders and lifters, is indispensable. Ensuring concurrence on parting lines is paramount for seamless mold operation.

Surface Finish Specification and Engraving Requirements

Articulation of desired surface finishes, which may encompass a spectrum of options, is crucial. Likewise, delineating the location and content of requisite engravings is imperative for achieving desired outcomes.

Injection Molding Materials

Discover a variety of options in our Injection Molding Material selection, featuring over 50 stocked types. We provide quality and efficiency to meet your project's specific needs.

Plastic Material

ABS
PC (Polycarbonate)
PP (Polypropylene)
POM (Acetal)
PE (Polyethylene)
PS (Polystyrene)
PVC (Polyvinyl Chloride)
PU (Polyurethane)
PA (Nylon)
PMMA (Acrylic)
HDPE (High-Density Polyethylene)
LDPE (Low-Density Polyethylene)
PC/ABS (Polycarbonate/Acrylonitrile Butadiene Styrene)

Rubber Material

Silicone
EPDM (Ethylene Propylene Diene Monomer)
Nitrile (NBR)
Neoprene (CR)
SBR (Styrene Butadiene Rubber)
Natural Rubber (NR)
Butyl Rubber (IIR)
Viton (FKM)

Thermoplastic Elastomer

Injection Mold Surface Finishes

We primarily offers SPI finishes for plastic injection molds. For VDI textures, specify your requirements when submitting your quote on our platform.

SPI Finish Standards	Surface Roughness RA (mm)	Finishing Method	Texture	Steels Recommended
SPI A1	0.012 to 0.025	6000 Grit Diamond	Super High Glossy finish	S136 (54HRC) or 8407(52HRC)
SPI A2	0.012 to 0.025	3000 Grit Diamond	High Glossy finish	S136 (54HRC) or 8407(52HRC)
SPI A3	0.05 to 0.10	1200 Grit Diamond	Normal Glossy finish	S136 (300HB) or 718H
SPI B1	0.05 to 0.10	600 Grit Paper	Fine Semi-glossy finish	718H
SPI B2	0.10 to 0.15	400 Grit Paper	Medium Semi-glossy finish	718H
SPI B3	0.28 to 0.32	320 Grit Paper	Normal Semi-glossy finish	718H
SPI C1	0.35 to 0.40	600 Grit Stone	Fine Matte finish	718H
SPI C2	0.45 to 0.55	400 Grit Stone	Medium Matte finish	718H
SPI C3	0.63 to 0.70	320 Grit Stone	Normal Matte finish	718H
SPI D1	0.80 to 1.00	Dry Blast Glass Bead	Satin Textured finish	718H
SPI D2	1.00 to 2.80	Dry Blast	Dull Textured finish	718H
SPI D3	3.20 to 18.0	Dry Blast	Rough Textured finish	718H

Plastic Parts Surface Treatment

Plastic surface treatment processes serve to enhance both the visual appeal and functional properties of plastic products. Each method offers distinct advantages:

■ Frosting: This process imparts a matte finish, enriching the tactile feel and visual texture of the surface.

■ Polishing: By achieving a mirror-smooth surface, polishing enhances the product's brightness and overall aesthetic appeal.

■ Spraying: Through the application of colored or transparent coatings, spraying not only improves appearance but also enhances durability against abrasion and corrosion.

■ Printing: Utilizing advanced printing techniques, intricate patterns or informative text can be added to the surface, enhancing its decorative and communicative aspects.

■ Stamping: Embossing metallic or colored patterns onto the surface adds a touch of sophistication and texture to the product.

■ IMD (In-Mould Decoration): This method seamlessly integrates decorative patterns directly into the plastic mold during the molding process, ensuring long-lasting durability and aesthetic appeal.

■ Electroplating: By depositing a metallic layer onto the surface, electroplating enhances both the visual and functional characteristics, including texture and corrosion resistance.

■ Sun Printing: This innovative UV curing printing technique allows for the rapid and precise application of multi-color patterns, ideal for achieving intricate designs with swift curing times.

Quality Control（QC）

In the injection moulding production process, quality inspection is a key component to ensure that the product meets the design specifications and quality standards.Xinjuexin quality inspection process involves not only finished product inspection, but also raw material inspection, production process control and final product inspection and other stages.

Raw Material Inspection

Raw Material Quality Inspection: Before production begins, raw materials are inspected to ensure that they meet production requirements. This includes testing the physical and chemical properties of the plastic pellets, such as melting point, flow rate, colour stability, etc.
Supplier Evaluation: Suppliers are evaluated and audited on a regular basis to ensure that the raw materials they provide are of a consistently high quality over time.

Production process control

On-line monitoring and testing: Real-time monitoring of the production process, such as dimensional accuracy, colour consistency, physical properties, etc., is carried out by setting up testing points and using automatic testing equipment.
Process Audit: Regular audits of the production process, including operator practices, maintenance of machinery and equipment, and cleanliness of the production environment.

Final Product Inspection

Dimensional and Appearance Inspection: Conduct dimensional measurements and appearance inspections of completed products to ensure that there are no defects, such as fusion lines, air bubbles, discolouration or deformation.
Functionality Test: Test the functionality of the products to ensure that each product works properly and meets the design requirements..
Durability and Reliability Test: Test the durability and reliability of the products by simulating the conditions of long-term use, such as heat resistance, cold resistance, chemical resistance and mechanical strength.

Packaging and final pre-shipment inspection

Packaging Inspection: Ensure that the products are firmly packaged with appropriate protective measures to prevent damage during transport.
Pre-shipment sampling: Random sampling before final shipment to ensure that the quality of mass-produced products is consistent with the samples.

Injection Molding Process At Xinjuexin

See how RapidDirect processes your orders, from quotation, high-quality injection mold making, to production-grade plastic parts, ensuring timely delivery with our skilled team and machinery.

Receive product drawings

After the customer sends the product drawings, the product is initially evaluated and quoted. If necessary, we can sign NDA agreement to protect customer's intellectual property rights.

Feasibility assessment and DFM report

A team of engineers will conduct a detailed feasibility assessment of the customer's design and provide a DFM (Design For Manufacturing) report. This is to ensure that the design is realisable prior to production and also to help the customer understand any design adjustments that may be required.

Design the mould drawings and make the moulds

After the DFM report has been approved by the customer, work will begin on designing the mould drawings and making the moulds.

Trial production and testing

After the moulds are made, trial production is carried out and samples are tested to ensure that the dimensions and performance meet the requirements. If the test fails, necessary mould modifications or moulding parameter adjustments will be made, and then the test will be repeated until the sample meets the requirements.

Customer Confirmation Sample

Successful test samples are sent to the customer for final confirmation to ensure that the product fully meets the customer's expectations.

Quality inspection and production

Once the samples have been approved by the customer, raw material procurement and quality inspection begins, followed by the production process of mixing, moulding, trimming, etc., and several quality inspections are carried out during the process to ensure product quality.

Assembly and packaging

After completing the production, the necessary assembly and packaging work is carried out to prepare the product for final shipment.

Shipment Preparation

Once the entire order is ready, a packing list is sent to the customer to assist in arranging shipment.

Why Choose Us

No MOQ

No minimum order reguirement helps move plastic molded partsfrom design to production in a fast turnaround and supports youron-demand injection molding needs with reduced cost.

High Quality and Consistency

Owing lsO certified factories, conducting in-process inspectionsand dimensional verification after production, guarantee thecustom molded parts consistency regardless of the complexshape with high precision.

Fast Turnaround

With certified domestic factories and a strong supply chainsystem, we accelerate the product development cycle andbridge plastic parts production as fast as 2 weeks, or less.

Injection Molding Expertise

Collaborate with our experts, boasting 10+ years in injectionmolding, for mold design guidance, material and finish choices,ensuring a smooth transition from prototyping to production.

FAQS

Star Rapid Injection Molding Service FAQ

These are the common injection molding questions at Star Rapid.

How long does it take to make an injection mold tool?

This depends on the complexity of the tool design and the type of material the tool is made from. Generally speaking, a very basic square shape made from relatively soft steel such as P20 can be made in less than one week. Very hard steels take longer to cut and to heat treat, while complex shapes or advanced surface textures can require three or more weeks to prepare.

What should you expect from a plastic mold manufacturer?

A reputable manufacturer will positively identify all incoming raw materials, and will carefully control every stage of production to ensure process repeatability. Full ISO certification is a good demonstration of their commitment to excellence.

How can I reduce mold costs?

A product developer should be looking to save money on the cost of a mold tool. In most cases, a less expensive tool is going to be of poorer quality, less durable, with looser tolerances and a bad surface finish. These are not cost-savings. Instead, they’re expensive mistakes. Rather, savings can be made long-term through production efficiency, fast cycle times, and process stability. As volumes increase, the relative cost of the tool goes down until it’s almost free.

What makes Star Rapid’s injection molding service special?

Our molding service is strengthened by our extensive expertise and a wide range of production capabilities. Our industry-leading facilities allow us to handle projects ranging from micromolding (10 tons) to large projects over 500 tons. This means we’re capable of producing parts ranging from millimeters to cubic meters in size. Our production of such a wide variety of parts enables us to best meet your needs. Further, we have unique access to tooling experts with decades of experience. They are available for video conferencing and customer support. We’re united in our efforts to help you have a satisfactory injection molding experience!

What types of tools and resins do you offer?

We make tools and dies from S136H, 2316H, H13 hardened, 2316H, P20, 8407, and NAK80 semi-hardened steels. We offer standard SPI finishes, EDM texturing, and several different types of etched textures. We also have thousands of thermoforming plastics available – contact us for details.

Can Star Rapid provide design services, industrial design support, or product development support as an extension of their molding services?

All orders are carefully reviewed by our tooling engineers to provide design for manufacturing optimization. We also work closely with outside design consultancies who can offer expert advice on the process of moving a product from the concept stage to production-ready.

What are Star Rapid’s quality standards for plastic injection molding services?

Our quality-control system includes several steps to ensure safe, high-performing products for our clients. As with all of our services, we conduct comprehensive material verification and testing before molding begins. This includes the metal used in our molds and the plastics used in production. During production, we carefully control all processing conditions — including temperature and humidity — to maintain repeatable results. Many molding companies neglect to do this, which can lead to flaws in the finished parts. We also 3D scan complex shapes to ensure accuracy.