Injection Molding
XTPROTO’s IM service provides custom quality parts quickly and accurately in conformance to customer requirements. Every IM project has a dedicated global team that gives each customer visibility into the entire process and ensures projects run smoothly from DFM to production to final delivery.
Online Injection Molding Services Custom Parts
Since 2012, XTPROTO has set the standard for the custom plastic injection molding industry. We specialize in the fabrication and production of close tolerance molds. Our engineering design team can take your project from concept to design by supporting our customers with design for manufacturability and mold flow analysis. XTPROTO has a full-service tool room to assist you with mold design, prototyping, and mold fabrication. We have over 100 state-of-the-art injection molding machines ranging from 28 tons to over 3,000 tons, including 15 overmolding machines.
XTPROTO custom injection molding services include rapid delivery of prototypes and low-volume production components. Due to our streamlined production process, we typically deliver our first batch in less than 13 business days, and simple expedited projects can be delivered in as little as five days.
Production Injection Molding
Cost Down Analysis
We partner with you to do cost down analysis to meet your requirements. Our global network enables Fictiv to optimize for “landed costs” of the product.
Dedicated Global Team
Manufacturing Engineers, Technical Program Mgt, SQE, Tooling Engineers, Logistics Supervisors assigned to each production program.
Complete Quality Systems
APQP full program planning, PPAP, Scientific Molding, Tooling inspection, and Automation. Access to ISO 9001:2015 quality certification and manufacturing partners certified to AS9100 Rev D, ISO 13485:2016, and IATF 16949:2016
Injection Molding Processes
Make the move from prototyping to on-demand manufacturing for affordable, high-quality molded parts within days. Better yet, your prototyping tool is free once you shift to an on-demand manufacturing tool. Working with a single supplier that provides free design consultation services also massively speeds up the manufacturing process, allowing for greater supply chain flexibility, more consistent parts, and making qualification a breeze.
Injection Mold Tooling
Overmolding
Insert Molding
Design support from part to mold
We are an end-to-end partner in the production of injection-molded plastic components, providing expert support part design and mold design. Our design support services leverage a number of specialized technologies, including design for manufacturing (DFM), design for assembly (DFA), design for disassembly (DFD), as well as a range of computer-aided design tools.
The productivity and service-life of a molded part has a direct correlation to the quality of the tools employed. Our high-quality, in-house mold-making capabilities boost production efficiency and ensure a seamless translation of design specs into molded parts. Our skilled engineers employ state-of-the-art mold making equipment to develop a range of high-quality tools, including multi-cavity molds, hot-runners, insert- and overmolding systems, improving part longevity while also reducing time-to-market.
Our Injection Molding Solutions
XTPROTO’s plastic injection molding services offer comprehensive solutions to meet a wide range of project needs, from rapid prototyping verification to mass production to accommodating geometrically complex parts.
We have many years of experience and a network of in-house manufacturing facilities focused on injection molding. It is the best way to cost-effectively mass-produce plastic parts. Our processes ensure consistent quality from small batches to large-volume manufacturing needs.
Quick Molded Parts
- Ships within 1 week
- Tool life: 250 parts
- Parts in production grade material
- Design/geometry limitations
- Max. part size: 80 x 80 x 50mm
- Over 150 materials in stock
Prototyping
- Ships 2 – 6 weeks after PEG approval
- Tool life: 2,500 parts
- Parts in real production grade material
- No geometry limitations
- Max. part size: 500 x 500 x 100 mm
- Guaranteed tool accuracy
- Hand loads
Production
- Ships 4 – 8 weeks after PEG approval
- Custom Quality Inspections and Standards
- Tool life: 10,000 to millions of parts
- Parts in production grade materials
- Materials can be supplied by customer
- Max. Part size: 1500 x 1000 x 350mm
- Guaranteed part accuracy
- Automated tools
Injection Molding Materials
We have over 100 thermoplastic and thermoset materials to choose from. If you are looking for an alternative material or a material we do not list, please contact XTPROT’s materials engineers.
- ABS
- ABS/PC
- Acetal
- Acetal Copolymer
- Acetal Homopolymer/Delrin
- ETPU
- HDPE
- LCP
- LDPE
- LLDPE
- Nylon
- PBT
- PC/PBT
- PEEK
- PEI
- PET
- PETG
- PMMA (Acrylic, Plexiglas)
- Polycarbonate
- Polypropylene
- PPA
- PPE/PS
- PS
- PSU
- TPU
Custom Injection Mold Finishes
Standard Finish
Moldmaker’s choice of finish. Typically SPI B-2, depending on geometry and drafts. Interior, non-cosmetic faces, are typically as-machined.
SPI Finishes
Range of Society of Plastics Industry (SPI) finishes from Grade 3 diamond / high polish to 320 stone low polish. Finishes include: SPI A-1, SPI A-2, SPI A-3, SPI B-1, SPI B-2, SPI B-3, SPI C-1, SPI C-2, SPI C-3, SPI D-1, SPI D-2, and SPI D-3.
MoldTech Finishes (Mold Texturing)
Range of finishes including matte, swirls, lines, and patterns. Our most common texture finishes include: MoldTech MT11010, MoldTech MT11020, and MoldTech MT11030. Other textured finishes can be added by request.
Other Textures - VDI
VDI 3400 Surface Finish (commonly known as VDI surface finish) refers to the mold texture standard set by Verein Deutscher Ingenieure (VDI), the Society of German Engineers. This is mainly processed by EDM machining, producing fine to coarse matte finishes.
As Molded
No secondary polishing or grinding. Part will show tooling marks.
Threaded Inserts
We can install most commonly used standard inserts in UNF and metric sizes.
Pad Printing
Transfer a 2D image onto a 3D part. All images are subject to review.
Laser Engraving
Engrave part numbers, logos, and more onto your parts.
Assembly
XTPROTO has the ability to assemble and label injection molded parts. Discuss your needs with your salesperson.
What is Injection Molding?
Injection molding is a manufacturing process used to produce precise, cost-effective parts, typically from plastics, in high volumes.
The process involves injecting molten material into a custom-designed mold, which defines the part’s shape. Once the material cools and solidifies, the mold opens and the part is ejected.
This process is ideal for creating complex parts with tight tolerances, making it popular in industries like automotive, medical devices, and consumer goods.
The Plastic Mold Manufacturing Process
The injection molding process starts with plastic resin pellets. The resin is heated to a molten state and then shot into mold. The plastic pellets are loaded into a hopper that is used to supply the injection-molding machine. The pellets are gravity-fed from the hopper into a heated chamber called the barrel where they are melted, compressed, and injected into the mold’s runner system by a reciprocating screw. A runner refers to the channel in the mold used to deliver the molten plastic to the mold cavity.
The granules are slowly moved forward by a screw-type plunger and the melted plastic is forced through a nozzle that connects to the mold sprue bushing, that controls the flow of material, allowing it to enter the mold cavity through a gate and runner system.
The metal mold is kept at a lower temperature so the plastic will solidify almost as soon as the mold is filled. The part cools and hardens to the shape of the mold cavity. The two halves of the mold, Side A and Side B, or the Cavity and the Core, open up and ejector pins push the part out of the mold where it falls into a bin. The mold is then closed and the process begins again.
Injection Molded Parts Delivered In Days
Our advanced mold making process is exceptionally efficient due to our proprietary manufacturing concept and team of process experts. Typically we are able to reduce the CAD to Injection Molded Part time by over 75% compared to traditional injection molding approaches. The overwhelming majority of our customers receive their injection molded parts in 15 days or less. To be clear, we produce molded parts using standard injection molding equipment with the resins our customers specify in two state of the art facilities in the United States. There is no trick, we just work extremely efficiently.
Request Your Free Injection Molding Quote Today
After receiving your drawings, our engineers will analyze your custom plastic injection molding parts right away. We actively work with you to clarify all details before providing a quote that is both economical and accurate.