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Injection molding is an industrial manufacturing process for producing plastic parts in large quantities. A thermoplastic material is heated, liquefied and injected under high pressure into a precisely milled metal tool (mold). After cooling, the solid component is removed from the mold - and the injection-molded part is finished.

The procedure is particularly suitable for:

• Complex geometries
• repeatable series production
• technically or optically demanding parts

Depending on the tool and machine concept, high quantities with very short cycle times are possible. Typical applications range from electronic housings to automotive parts and medical technology components.

Two aspects are important in the production of injection molded parts. Firstly, the component-specific dimensions are important. These include wall thicknesses, slide areas and feed points. 

Secondly, the dimensional tolerances and shape and position tolerances are crucial. These depend largely on the material used, the tool concept and the process-related influences.

In practice, the Tolerance grade TG 6 to TG 8 according to DIN ISO 20457 can be used. Angle tolerances are usually ±0.5° to ±1°. Concentricity and axial run-out tolerances are limited by the demoldability and accuracy of the tool - especially for rotationally symmetrical components.

The following are used to determine the tolerance Standards and guidelines relevant:

• DIN ISO 20457 - General tolerances for plastic injection molded parts
• DIN ISO 2768-mK - for low-function components without special requirements
• Customized drawings, e.g. according to PPAP or VDA guidelines, are common for high-quality applications

The achievable precision depends largely on various factors. Particularly decisive is the Shrinkage of the plastic. This is the case with materials such as PA (polyamide) significantly more pronounced than with ABS or PC. 

The Wall thickness influences the dimensional accuracy. Very thick areas can cause sink marks, while zones that are too thin make the filling process more difficult. In addition Mold temperature, injection pressure and cycle time plays a central role in dimensional and shape accuracy.

Injection molding is particularly economical for Medium to large quantities. Typically, the procedure is worthwhile from around 300-500 parts. This is because the tool costs can then be passed on to the series. 

For very large quantities (>10,000), injection molding is almost unbeatable in terms of unit costs, reproducibility and cycle time. For prototypes or small series, FACTUREE also offers Rapid Tooling with reduced tool costs.

For smaller quantities or early development phases, alternatives such as 3D printing (e.g. SLS, SLA, MJF) or Vacuum Casting meaningful. 

For flat or simple parts, the CNC machining be economical. FACTUREE offers all three processes - ideal for early validation before the transition to injection molding.

There are a variety of tools for injection molding, which are used depending on the number of pieces, complexity and component requirements.

For prototypes or small series we recommend Aluminum tools with a short lead time. For series with higher quantities (>10,000), we use Hardening steel tools for use. Single, multiple and family molds are possible, with hot runner or cold runner technology.

FACTUREE processes a large selection of thermoplastics, including:

• Standard plastics such as PP, PE, ABS, PC, PA, POM
• Engineering plastics such as PBT, PC/ABS, PPS
• Extremely resilient plastics such as PEEK, LCP
  Also TPE (soft), filled compounds (e.g. glass fiber reinforced) and UL-certified types are available. We can test other special materials on request.

FACTUREE offers both Procurement of tools (e.g. high gloss, graining, matting) as well as Subsequent refinements, including:

• Lacquering / Softtouch
• Galvanizing / Metallizing
• Pad and screen printing
• Laser Engraving

FACTUREE manufactures according to DIN EN ISO 20457 (Injection molding of thermoplastics) and DIN ISO 2768 for dimensional tolerances (freely dimensioned plastic parts). For special projects, we can incorporate your specific requirements. These include, for example, special dimensions, specific materials or tests in accordance with VDA, PPAP or FDA regulations.

Yes - FACTUREE works with certified manufacturing partners according to ISO 9001 (quality management). Depending on the industry and application, partners with IATF 16949 (Automotive) or ISO 13485 (medical technology) can be consulted. The selection is made according to the respective requirements of the project. Read more about certifications and test reports at FACTUREE here.

Yes - FACTUREE will provide the following documents on request:

• Initial sample test report (EMPB) according to VDA or PPAP
• Material certificate / factory certificate 3.1 (EN 10204)
• Measurement protocols or CT scans for complex geometries
• Protocols for head chefs for finished parts.

This evidence should be provided at the time of the inquiry so that it can be taken into account in the production process.

Simply upload the CAD file with the technical drawing, select the material and make an online inquiry. FACTUREE connects you digitally with the right manufacturing partner from a network of over 2,000 companies. Production is ISO-certified - fast, precise and reliable.

Online production has become indispensable these days. For cast parts, online production offers numerous advantages: 

• Fast production of customized castings: often with delivery in 9-12 working days.
• High precision for complex geometries
• Cost efficiency for prototypes and series: No tooling costs for casting; low unit prices thanks to smart paver selection.
• Variety of materials for every requirement - everything can be ordered digitally.
• Flexibility with quantities and variants: Individual parts, variant production or mass production - without long lead times.
• Perfect for recurring components: Framework agreements and price stability for series parts or maintenance components
• Seamless integration into digital development processes: Simple upload of DXF, STEP or STP files, automatic checking and quotation generation
• Quality control and ISO certification: Manufacturing partner with proven quality and reliable delivery