Plastic injection molding is a manufacturing process that involves the process of injecting melted plastic resins into a prefabricated mold to create a variety of parts and components. This highly versatile and cost-effective process is used to manufacture a variety of products, from children’s toys to complex engineering components.
For more than 35 years, Lerner Molded Plastics has been a leading provider of plastic injection molding services for customers in a wide range of industries. Our state-of-the-art facility allows us to produce quality injection molded parts from the initial design phase through full-scale production and distribution. Whatever your needs, we have the knowledge and skill to create your product or component with the utmost speed and efficiency, all while staying within your budget.
To help you determine whether plastic injection molding is the right choice for your project, we have created a comprehensive guide to the plastic injection molding process, materials, and benefits.
Plastic Injection Molding Process
Plastic injection molding uses high pressure and heat to force melted plastic into a heated mold, where it takes on the desired shape as it cools. The cooled product is smooth and often requires very little additional processing. Although the details of the process may vary depending on the product and material, the plastic injection molding process typically follows these six steps.
1. Mold Creation
A mold is manufactured from a durable, heat-resistant material such as aluminum, steel, or beryllium-copper alloys. Molds are typically CNC machined and finished to extremely precise dimensions to ensure highly accurate and repeatable molded products. Injection molds can be designed with single or multiple gates, through which the melted plastic is injected, and must be able to open on a hinge or sandwich design to allow for part ejection once it has cooled.
To ensure that the mold does not expand, contract, or become separated when exposed to the high temperatures and pressure of injection molding, the mold must have a secure clamp. The clamping force must be calibrated to ensure that the melted plastic can be injected with enough force to completely fill every part of the mold without material leakage.
The injection process is initiated when plastic beads, powder, or pellets are placed in a hopper, which feeds the material into a heated barrel, causing the plastic to melt while the turning screw simultaneously propels it toward the injection head. The injection head deposits a specific amount of molten resin into the mold at high pressure to ensure that the mold is completely filled.
After the resin is injected into the mold, the mold is allowed to cool. The plastic hardens as it cools, solidifying into the desired shape. The cooling process is calibrated to ensure that the material cools at the right pace to produce optimal shape, hardness, and surface finish.
The cooled part is ejected from the mold using built-in ejection pins. It is important to ensure that the part is thoroughly cooled in order to avoid damage. Ejection timing is based on the required cooling time for a given part’s size, shape, and material.
Plastic injection molded parts are ejected with a smooth surface that requires very little finishing, though specialty coatings and finishes may be added for specialized applications. Most often, the only finishing necessary is the removal of excess plastic around the channels where the resin was injected.
Plastic injection molding can be used to manufacture parts from a wide range of materials, including:
High Density Polyethylene (HDPE). A versatile, affordable thermoplastic with high tensile strength and stiffness, HDPE is waterproof, resistant to microbial growth, chemically resistant, and offers good electrical insulation.
Polypropylene (PP). PP is a rigid, crystalline thermoplastic valued for its high strength-to-weight ratio, stiffness, electrical resistance, and chemical resistance. It also bears stress and has high impact resistance.
Polystyrene (PS). A low-cost thermoplastic with high strength and exceptional clarity, PS is useful for clear packaging and lab equipment, or can be colored for use in consumer products.
Nylon. Nylon is an extremely versatile thermoplastic blend that can be tailored to meet the needs of particular products. Nylon blends are extremely tough, with high chemical and thermal resistance and low friction.
Acrylonitrile butadiene styrene (ABS). ABS is an affordable engineering thermoplastic valued for its structural strength, stiffness, impact resistance, chemical resistance, thermal resistance, and electrical insulation.
Acetal. Acetal isa strong, tough semi-crystalline thermoplastic with exceptional chemical resistance, high mechanical stability, extreme creep resistance, and a low friction coefficient.
Polycarbonate (PE). PE is a highly durable amorphous thermoplastic with extreme dimensional stability, good impact strength, exceptional optical clarity, and good electrical insulation.
Polyester (PET / PETG). Polyester is an extremely stress-resistant semi-crystalline thermoplastic with high dimensional stability and exceptional resistance to chemicals and heat.
Acrylic. Acrylic is an extremely transparent thermoplastic with high resistance to UV radiation, exceptional impact strength, and high dimensional stability.
Advantages of Plastic Injection Molding
Plastic injection molding is an extremely efficient and cost-effective process that can be used to create extremely complex components with a high degree of accuracy and repeatability. Some of the benefits of plastic injection molding include:
Efficiency. Plastic injection molding uses the same mold for multiple runs, making it a quick and efficient way to produce multiple components. In addition, products straight out of the mold typically have a smooth finish that requires very little additional processing, thereby reducing time and labor.
Accuracy. Since the plastic resin is injected into the mold at high speed, it is forced to fill every cavity in the mold, ensuring extreme accuracy on even the most complex components.
Less Waste. Leftover thermoplastic material from the plastic injection molding process can be added to the next load, thereby eliminating process waste. In addition, many of the thermoplastics used in injection molding are recyclable, reducing overall waste.
Low Costs. Injection molding uses the same molds for multiple products, making it less expensive than many other manufacturing processes.
Variety of Material and Color Options. A wide variety of plastic materials and blends can be used in the plastic injection molding process to create products in nearly any color.
Plastic Injection Molding Industries and Applications
The versatility, accuracy, repeatability, and many other benefits of the plastic injection molding process make it a popular manufacturing choice for numerous industries, including:
Building and construction for pipes, fixtures, hand tools, pulleys, and sprockets.
Food and beverage for packaging, bottles, line process equipment, and dispensing equipment.
Medical and pharmaceuticals for medical devices, surgical implements, and packaging for medical equipment and pharmaceuticals.
Automotive for interior handles, knobs, and fixtures.
Consumer goods for appliances, garden supplies, tools, furniture, and decor.
Housewares for disposable and reusable silverware, plates, bowls, cups, and mugs.
Toys for building blocks and other brightly colored children’s toys and games.
Expert Plastic Injection Molding Services From Lerner Molded Plastics
At Lerner Molded plastics, we pride ourselves on providing our customers with the highest quality injection molding services and materials in the industry. From very small tight tolerance parts to extremely large products requiring high tonnage clamping forces, we have the equipment and experience to handle any size part requirement. As an industry-leading plastic injection molding company, it is our goal to ensure reliable, repeatable products that meet even the most stringent industry standards and specifications. Whether you are in need of large-scale production of a simple toy design or intricate custom OEM components for industrial manufacturing, we have the equipment, experience, and skill necessary to provide you with exceptional quality components every time.
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If you want to know how to mold large plastic parts with precise, cost-effective methods, Lerner Molded Plastics can help. Lerner is a leading manufacturer of large plastic parts in Northeast Ohio.
Our staff combines countless years of experience in the plastic parts manufacturing industry. So, we can offer our customers the highest quality for their components. We also offer competitive prices to remain within your budget.
Lerner provides a wide variety of high-precision molding processes to create the parts you need. Our manufacturing processes include injection molding, blow molding, compression molding, extrusion molding, rotational molding, and thermoforming. Additionally, we offer custom coloring services for thermoset and thermoplastic processing.
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Lerner Molded Plastics is a leading provider of injection molding services for larger components. As one of the leading groups of large injection molding companies, Lerner offers each client the highest possible quality for their injection molded parts. Our injection molding capabilities enable us to develop large part injection molded solutions for any industry or application.
With a state-of-the-art, ISO Certified facility, we deliver high-quality injection molded parts in a wide variety of plastic materials. Lerner also specializes in complex, multi-cavity molds. As a result, we can fulfill requirements for products ranging from small to very large with shot sizes from 3 to 600 ounces. Our facility houses advanced injection molding machines with clamping forces ranging from 30 to 3,000 tons and up to 64 cavities.
Additionally, Lerner offers injection molding processes for thermoset and thermoplastic materials with custom colors. We are a full-service provider of injection molding services, so we can assist with every stage of the process, from engineering to product development. Furthermore, Lerner offers tooling and mold making as well as finishing, logistical support and supply chain management services.
With 25+ years of experience as one of the leading large injection molding manufacturers, we can help you create exceptopma; designs to maximize quality and minimize production costs. We also offer a veriety of high-quality plastic materials:
High-Density Polyethylene (HDPE)
Lerner has the equipment an resources to help you create the components you need, regardless of your industry or application.
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Need large custom plastic parts for your next project? Consider large scale injection molding from Lerner Molded Plastics
Large Scale Injection Molding and Other Services from Lerner Molded Plastics
Lerner Molded Plastics can accommodate shot sizes from 3 to 600 oz. with clamping forces of 30 to 3,000 tons. Partner with Lerner Molded Plastics for premier mold formation, quality tooling, and reliable supply chain services and finishing operations. From custom colors to the most detailed multi-cavity molds, Lerner Molded Plastics has everything you need. Customers count ont he Lerner team for services including:
Lerner Molded Plastics has a reputation as a top-quality provider of injection molding services for customers in a variety of industries. Their ISO certified, state-of-the-art facility produces injection molded components from a wide range of plastics.
As a provider of blow molding services, Lerner Molded Plastics offers equipment in single or dual head configurations with up to a 40-lb. capacity. Their shuttle press systems are utilized for high-volume production, and their capabilities can accommodate components that feature multiple cavities in various sizes.
Lerner provides quality OEM, automotive, and consumer products. Lerner specializes in manufacturing single, co, and tri-extruded plastic profiles, pipes, and tubes. Applying a combination of materials to meet the requirements of flame-retardant and food-grade applications. Lerner’s facility can accommodate anything from prototypes to high-volume runs.
Lerner provides precision thermoforming services to a wide variety of industries. They use advanced equipment for thin-gauge, high-production output thermoforming. Rotary machines and single station equipment is used for heavy-gauge thermoforming.
Rotational molding is a highly desirable option for manufacturing large parts with lower volumes. Lerner provides rotational molding services to customers int he OEM, automotive, and consumer products industries.
Design and Construction of Tooling
Lerner Molded Plastics provides mold design services for injection molding, blow molding, rotational molding, thermoforming, and extrusion. Their capabilities include anything from small precision tools to large, single-cavity tools.
Supply Chain Services
Lerner offers complete supply chain services, including local sourcing of all raw materials, sub-assembly components, packaging, warehousing of finished products, and direct drop ship capabilities.
What is Plastic Injection Molding? | Large Scale Injection Molding
Plastic injection molding refers to the manufacturing process used to produce a large volume of identical parts. With large scale injection molding, manufacturers can produce parts of a variety of sizes and shapes, including small and large part molding. Injection molding is extremely versatile and has several advantages when compared to other plastic molding methods.
To list, some of the advantage of choosing plastic injection molding over another fabrication method include:
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Are you looking for large part molding specialists in Northeast Ohio? Lerner Molded Plastics is a leader in Ohio’s leading plastic parts manufacturing companies. We provide our clients with precision, custom plastic injection molding services for the highest quality components. In fact, our plastic molding capabilities give us the ability to develop effective solutions for any application with competitive pricing.
Our ISO 9001 2015 certified facility provides custom molded plastic parts with various different materials. Also, Lerner Molded Plastics specializes in production with multi-cavity molds. As a result, we can effectively produce high volume small and large parts with shot sizes ranging from 3 to 600 ounces. Furthermore, our full-service manufacturing facility houses state-of-the-art plastic molding machinery with 30 to 3000-ton clamping forces and as many as 64 cavities.
As the leading large part molding specialists in Ohio, with a series of high tonnage presses for injection molding. We also offer large part rotational molding, blow molding and thermoforming. Lerner offers thermoset and thermoplastic processing with custom coloring capabilities. Most notably, we can help our clients at each step of the plastics manufacturing process from prototyping to production. We also offer mold and tooling design services as well as finishing services, logistical support and supply chain management.
We have 25+ years of experience as large part molding specialists, so we can help our clients create optimal product designs that offer maximum quality with lower production costs. Lerner also has access to a wide variety of plastic materials:
High-Density Polyethylene (HDPE)
Polyester (PET / PETG)
Lerner Molded Plastics has the resources, equipment and expertise to help you make the plastic parts you need to fulfill your application requirements.
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Are you looking for a reliable large plastic parts manufacturer in Ohio? Lerner Molded Plastics can accommodate both small and large part molding. Lerner offers the necessary precision to produce large parts with custom specifications, so our customers always receive the highest quality components. Out molding capabilities also allow us to offer more cost-effective solutions so you remain within your budget.
Why choose Lerner’s large plastic parts molding specialists?
Lerner Molded Plastics can efficiently produce multiple parts of varying scales and shot sizes, ranging from 3 to 600 oz. Our manufacturing facility employs advanced plastic molding equipment with high-pressure clamping forces, ranging from 30 to 3,000 tons and up to 64 cavities.
We are a leading provider of injection molding in Ohio with a series of high-tonnage presses. Lerner Molded Plastics offers a variety of precision services, including rotational molding, blow molding, and thermoforming for small and large plastic parts, so we can create anything you need. We also offer custom coloring options for our thermoset and thermoplastic processing services.
Lerner plastics operates a state-of-the-art, ISO certified facility, accommodating injection molded components from the small to the very large.
This is a desirable option for manufacturing large plastic parts with lower volumes. Our equipment is capable of molding parts up to 35′ long and a weight of up to 175lbs., with single or multiple cavities.
Lerner’s blow molding capabilities accommodate components of varying sizes, including the very large. We utilize blow molding equipment in single or dial head configurations with up to 40lb. capacity.
At Lerner, we use advanced in-line equipment for thin-gauge high production output thermoforming and rotary machines and single station equipment for heavy-gauge thermoforming. Our equipment can accommodate components of up to 15′ in length.
Large Part Plastic Molding Advantages
Choosing a reputable plastic parts molding specialist will not only result in higher quality products but also reduced production costs. Lerner’s large part plastic molding services offer a variety of advantages:
Higher precision and tolerances
Diverse material selection
About Lerner Molded Plastics
Regardless of the part you need, we can help you with anything from the initial design phases to final shipments. At Lerner, our plastic part molding specialists have a reputation for consistently providing high-quality products and outstanding customer service.
We also offer supply chain services and 24/7 drop shipping to your customers’ locations. Our quality assurance programs consist of detailed-oriented documentation, traceability, and compliance with all of your application’s requirements. As a result, you will always receive the components you need with pricing that suits your budget.
If you’re searching for reputable plastic injection molding companies in Ohio, contact Lerner Molded Plastics today!
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High Press Tonnage Plastic Injection Molding Services
Choose the right injection molding company for your next large part molding project.
How to Choose a Plastic Injection Molder for your Project
Choose the right plastic injection molder for your project by identifying large part molding companies that can meet your project requirements. Facilities with a wide range of press sizes will be able to accommodate your needs. Look for a company that can design and build the mold, as they will ahve a better understanding of how to maximize the manufacturing process. Choosing the right injection molding company will ensure your project is done as efficently and cost-effective as possible.
Lage Part Molding from Lerner Molded Plastics
Lerner Molded Plastics operates an ISO certified, state-of-the-art facility, where they accommodate a variety of product sizes, from small to large plastic parts, with high tonnage presses. Lerner’s facility is equipped with presses that achieve clamping forces from 30 to 3000 tons, with up to 64 cavities.
Lerner Molded Plastics a Full Service Provider
Lerner Molded Plastics can also support production with capabilities such as engineering and product development. Additional services include mold making and tooling, finishing operations, supply chain management, and logistical support. See below for more information on each of Lerner’s services.
Lerner utilizes advanced blow molding equipment in single or dual head configurations with up to 40-lb. capacity. Their shuttle press systems can provide high-volume production, and their capabilities can accommodate components that feature multiple cavities of varying sizes.
Lerner’s custom plastic extrusion services provide quality OEM, automotive, and consumer products. Specializing in manufacturing single, co, and tri-extruded plastic profiles, pipes, and tubes. Lerner applies a combination of materials to meet the requirements of flame-retardant and food-grade applications. lerner is a UL-certified molder, operating an ISO certified facility to accommodate anything from prototypes to high-volume runs.
Lerner Molded Plastics provides precision thermoforming to a wide variety of industries, including OEM, consumer products, automotive, and more. Advanced equipment is used for thin-gauge, high-production output thermoforming, and rotary machines and single station equipment is used for heavy-gauge thermoforming. Manufacturing capabilities include components up to 15′ long, accommodated with both male and female tooling. Accurate trim tolerances can be met with CNC trimming equipment.
A highly desirable option for manufacturing large parts with lower volumes. Lerner provides rotational molding services to customers in the OEM, consumer products, and automotive industries. Lerner’s rotational molding equipment is capable of molding parts up to 25′ long, and up to 175 lbs., with single or multiple cavities, in custom colors.
Tooling Design & Build
Lerner provides mold design services for injection molding, blow molding, thermoforming, rotational molding, and extrusion. Manufacturing capabilities include small precision tools to large, single-cavity tools. They also fabricate checking and assembly features.
Secondary services offered by Lerner include decorating – hot stamping, complete electronics assembly and packout capabilities.
Supply Chain Services
Complete supply chain services offered by Lerner include local sourcing of all raw materials, packaging, sub-assembly components, warehousing of finished products, and direct drop ship capabilities to customers.
What is Injection Molding?
Plastic injection molding is a reliable manufacturing process commonly used for producing mass quanities of identical plastic parts. Injection molding gives manufacturers the ability to produce parts in a cariety of shapes and sizes, including small and large part molding. The process offers benefits such as low scrap rates and the ability to produce identical parts.
How Does Plastic Injection Molding Work?
An injection molding machine contains 3 parts: the hopper, the screw and a heated barrel. The hopper sends resin pellets through the heated barrel. The material is then melted by a screw outfitted with heaters. The palstic is injected through the nozzle into a mold cavity, where it solidifies to the configuration of the cavity. After the process is complete, the parts are boxed and shipped.
For more information about large part molding from Lerner Molded Plastics, please contact us today.
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Get high-quality parts at competitive prices when you partner with the right large part injection molded plastic suppliers
What is Plastic Injection Molding?
Injection molding is a manufacturing process generally used for the mass-production of parts. It is an efficient way to produce plastic parts in mass quantities. The shape and size of products achievable through the process of injection molding has evolved over time. When molding large parts, there are several details to consider.
If you are in search of a provider who can accommodate large plastic parts, you’ll need to take into account some considerations, such as: tolerance, manufacturing method, capabilities of available machinery, cost, as well as any other factors unique to your product(s).
Is Injection Molding Better Than 3D Printing? | Large Part Injection Molded Plastic Suppliers
3D printing forms three-dimensional objects through the sequential mechanized layering of build material, usually plastic. As technology has advanced, the additive manufacturing method has revolutionized modern manufacturing.
For large parts, in particular, you may find you benefit more from injection molding than 3D printing. Depending on the size of the necessary part, you could save significant time and money by opting for plastic injection molding. Large part printing cycles can take up to several hours while injection molding could produce the same part within a matter of seconds.
Some of the other drawbacks to 3D printing include limitations of volume and uneven surfaces. The size of a 3D printed part depends on the size of your 3D printer. However, with plastic injection molding, you have endless options when it comes to creating molds. In addition, 3D printing gives parts ridged layers that are not always ideal for parts that will do significant moving.
Large Part Plastic Injection Molding From Lerner Molded Plastics | Large Part Injection Molded Plastic Suppliers
The Northeast Ohio community of businesses has a distinct history of excellence in the plastic fabrication industry. For almost three decades, Lerner Molded Plastics has continued this legacy. In all, if you and your colleagues have been looking for reliable large part injection molded plastic suppliers, then you can feel confident in teaming up with Lerner Molded Plastics. To list, client businesses count on Lerner Molded Plastics for
Posted by sachin on | Comments Off on Outsourcing Large Injection Molding Projects
Have you been trying to choose between purchasing a large injection molding machine or outsourcing your project? Lerner Molded Plastics provides high-quality injection molding for all of your project needs.
Plastic Injection Molding Services from Lerner Molded Plastics | Large Plastic Molding Machines
Lerner Molded Plastics has a demonstrated history of excellence in the injection molding industry. For more than two decades, they’ve continued this legacy. When you partner with professionals at Lerner Molded Plastics, you’ll gain access to their knowledgeable and experienced team. The Lerner team provides efficient and ssteamlined processes for all customers, eliminating the need for them to move production in-house.
Cusromers depend on the dedicated team of experts from Lerner Molded Plastics for
Plastic Injection Molding
Both Tool Design and Build
Full Supply Chain Services
Post Molded Painting
Both Product Assembly and Packout
Bar Coding and Labeling
3 Advantages of Outsourcing Your Injection Molding
Manufacturers continue to utilize injection molding because of its versatility and accessibility. But how do you decide whether to purchase a large injection molding machine and keep production in-house, or to outsouce your production? In-house production can be costly and cause unforeseen problems. If you outsource your injection molding project, you’ll see benefits such as lower costs, improved quality, and production support.
1. Lower Cost
Obviously, you’ll need to purchase a large injection molding machine in order to produce parts in-house, which is a large investment. Outsourcing your plastic injection molding will allow you to save on the cost of new equipment, and may even bring benefits such as QA tools and packaging equipment. Additional time and money may be spent on your equipment for scheduled mainenance to keep running smoothy. Keep in mind that you will also need experienced personnel to operate your injection molding equipment if you keep it in-house, as opposed to outsourcing it.
2. Higher Quality Product
Outsourcing your injection molding to an experienced company means that you’ll have access to extensive expertise, which results in a high level of quality for your finished product. Any problems that arise could halt production and decrease efficiency; whereas outsourcing your production means someone else will troubleshoot these issues for you.
3. Production Support
Partnering with an experienced large injection molding machine company can mean the difference between a headache and a successful project. Injection molding experts can provide a cost-effective, streamlined process. Choose the right injection molding provider that will support you when you have questions or concerns.
What is Injection Molding?
Plastic injection molding is a manufacturing process for producing a large volume of identical parts. With injection molding, manufacturers can produce parts of a variety of sizes and shapes, including small and large part molding, using large plastic molding machines. Injection molding offers benefits that include low scrap rates and the production of identical parts.
For more information about large injection molding machine capabilities from Lerner Modled Plastics, or our other capabilities, please contact us today.