Capabilities

Injection molding services

A faster, easier way to order high-quality injection molded parts that accelerates iteration, testing, and scaled production. Upload your designs for DFM feedback and pricing in 1 business day.

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we’ve been experts in understanding the complexities of various plastic needs for our clients

Injection molding and all related services are performed by XTmade. Our offers a wide range of injection molding services to help our customers with their troubleshooting and production needs.

All samplings and production runs are setup based on scientific injection molding principles.

Our team of plastics engineers has extensive real-world experience with injection molding, product development, mold design and part design, and quality control.

Our presses range from 3 U.S. Tons to 330 U.S. Tons, and they support shot sizes from 0.1 oz to 20.86 oz.

Injection Mold Classes

We can fabricate injection molding tooling in aluminum — ideal for rapid low-volume prototyping — or tool steel. Molds adhere to SPI mold classification, which specifies the durability of tooling and for how many cycles it is suitable.

Standard injection mold tooling is defined by classes from Class 105 (prototype) to Class 101 (high volume production). These mold classes help manage expectations for both customers and suppliers on the overall tool requirements and scope.

Under 500 cycles. Prototype only. This mold will be constructed in the least expensive manner possible to produce a minimal quantity of prototype parts. Class 105 molds are also known as Class V tools.

Example: a one-and-done market test of 100 molded units.

Under 100,000 cycles. Low production mold. Use only for limited production, preferably with non-abrasive materials. Low to moderate price range. Class 104 molds are also known as Class IV tools.

Example: Aluminum or MUD tooling, SPI B-3 finish, hand-loaded cores, and limited re-runs.

Under 500,000 cycles. Medium production mold. This is a very popular mold for low to medium-production needs. Most common price range. Also known as a Class III tool.

Example: Aluminum or steel tooling, automated lifts or slides, multiple re-runs with batches between 1,000-5,000 units.

Medium to high production tooling, suitable for abrasive materials or parts requiring close tolerance. This is a high-quality, reasonably high-priced mold. Class 102 Molds are also known as Class II tools.

Example: Steel tooling with an SPI A-2 finish, automated slides, scheduled production cycles.

Over 1,000,000 cycles. They are engineered for extremely high production. This is the highest-priced mold and is made with only the highest-quality materials. Class 101 molds are also known as Class I tools.

Example: Multiple-cavity steel tooling with full automation and overnight production work centers for dedicated part manufacturing.

Explore our injection molding service

Professional Services

Insert Molding 350

Insert Molding

Metal(such as screws) and plastic components are combined into a single integrated part.
overmolding products 350

Overmolding

Two sets of molds, two injection cycles to complete the injection process of two different materials
Silicone Molding 350

Silicone Molding

Injection molding solutions for food-grade and medical silicone products for mass production

Injection molding materials

production capacity

We have wide selection of more than 100 thermoplastic and thermoset materials. And if you’re looking for alternative material options, check out our guide to resin substitutes for ABS, PC, PP, and other commonly molded plastics.

  • ABS
  • ABS/PC
  • Acetal
  • 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

The Plastic Injection Molding Process

Plastic injection molding is the process of filling a mold tool with liquid plastic resin under great pressure. The tool may comprise a single cavity or hundreds of cavities in order to make indefinite numbers of parts. Once the mold tools have been carefully designed and manufactured, the molding process consists of the following basic steps:

  • Step 1: The plastic resin comes in raw pellets. These are dried to the right moisture content, and then if necessary they can be blended with pigments or master batch colorants to create the correct color for the design.
  • Step 2:  The dried pellets are poured into the hopper of the molding machine. A reciprocating screw inside the barrel of the machine is used to transport these pellets towards the mold while at the same time heating them.
  • Step 3:  Within the barrel, the pellets are mixed and heated until fully molten, forming the liquid resin.
  • Step 4: The heated mold closes automatically and resin, under great pressure, is injected through a gate and into the mold cavity.
  • Step 5: The mold is cooled in a short amount of time to solidify the part inside.
  • Step 6: The mold opens and the part is ejected to begin a new cycle.

Injection Molding Finishing Options

Heat Staking

Heating plastic to reform it and insert a component (e.g., a threaded insert).

Laser Engraving

Engraving text or a design with a laser.

Pad Printing

Applying an ink-based, 2D design to a 3D surface

Painting

Applying primer, top coat, EMI (copper) paint, in both standard and Pantone colors.

Ultrasonic Plastic Welding

Joining or reforming thermoplastics with a
high-frequency welder

What is Injection Molding?

Injection molding is the process of injecting molten plastic into a mold cavity, rapidly cooling it, then ejecting the solidified plastic part. It is the most widely used manufacturing process for plastic parts and the most affordable route to mass production. Once the metal mold or tooling has been made, hundreds, thousands, or millions of plastic duplicate parts can be made in a short timeframe, with the effective cost-per-part reducing with each additional molding as the cost of the mold is amortized. Injection molding is compatible with a very wide range of materials — including thermoplastics, thermosets, and even metals — which can be easily mixed with color pigments and other additives to tweak the function and appearance of the moldings. Furthermore, the injection molding process offers excellent consistency between units, as the tooling remains constant throughout.

At XTmade, we offer a range of injection molding services, from affordable low-volume prototyping to part production, using thermoplastics, thermosets, or metals. Our team of experienced molding specialists can guide you to the right solution, whether you need rapid aluminum tooling for a fast prototype or a more durable solution for larger production runs. Unlike many molding companies, we do not specify a minimum order quantity.

Specializing in Low-Mid Volume Orders

  • We offer molding services with no minimum quantity requirements.
  • Any request from 20 to 250,000 components will be completed with care by our team.
  • We will advise you as best fits your unique project and its scale, to ensure affordability and efficiency. For example, to lower costs, a higher number of cavities may be recommended.
 
injection molding 9

Details of Our Low-Mid Volume Production Injection Molding Services

  • 100% First Article Inspection (FAI) provided if requested
  • We use all-electric molding presses with 85-390 tons of clamping force.
  • We offer 3D printed fixturing to help remove hand load insert for side pulls
  • Single to multi-cavity tools available
  • We utilize mud inserts for quick changeovers
  • Molded prototype parts with production mold quality are supplied with all orders
  • Your parts can be perfected with finishes, textures, custom colors, molded lettering, and more.
  • Additional quality control services are also available upon request.
  • Choose from stock materials or request specially sourced materials. We also work with customer-provided materials.

Injection Molding Applications

Served Industries

Automotive 350

Automotive

Automotive grade certified precision parts.
Consumer Products 350

Consumer electronics

First choice for new product launches.
Medical Devices 350

Medical and Dental

Medical grade certified precision parts.
Aerospace Industry 350

Aerospace & Aviation

Precision manufacturing boosts aerospace development.
Industrial Machinery 350

Industrial machinery

Multiple material choices make industrial parts more competitive.
Robotics and Automations 350

Robotics

Accelerate the development of the future robotics industry.

When you choose injection molding services from our team

You can rest assured your mold will be fabricated to the highest quality, to create
injection molded parts that meet your exact specifications.

Our Latest News

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