Custom Plastic Components
Plastic injection molding is a manufacturing process where raw thermoplastic polymers, in the form of resin, are melted and injected into a mold cavity. After the plastic cools and hardens, the mold is opened to remove the plastic components. Injection molding is a versatile form of plastic component fabrication that is used for a range of products including containers and packaging, toys, automotive components, and more. It is ideal for high volume production runs and the fabrication of detailed intricate parts.
The decision of choosing plastic components over metal or other materials depends on the design and intended used as well as required strength, wear resistance, heat resistance, and secondary operations that may be applied to the product. For many components, plastic is an excellent alternative that is less expensive by volume and provides several benefits including:
- Easy to form and machine
- Provides strength and durability
- Available in various colors
- Requires little to no finishing
- Has a faster production time
- Is a lightweight material
- Provides resistance to chemicals and corrosion
Custom Plastic Parts Manufacturing Using a Range of Materials and Processes
Ace Seal manufactures custom plastic parts using a range of processes including plastic injection molding. We serve a wide range of industries including aerospace, biotechnology, gas and oil, medical, and military and have the expertise to help you choose which material and fabrication process are right for your application. Some of the additional plastic manufacturing processes we perform include:
Overmolding: a manufacturing process where a substrate, usually plastic or metal, is overmolded with plastic or rubber to create a single component. This process is often used to create soft-grip surfaces on tools, toothbrushes and other products. Material compatibility must be considered when using the overmolding process, but a benefit is that two or more materials can be combined to create a single product.
Hot Runner Process: this process works the same as standard injection molding; the only difference is that is utilizes an assembly of heated components to fabricate custom plastic parts. Advantages of hot runner process injection molding include a shorter cycle time, fewer underfilled parts and a balanced melt flow to create consistent shapes within the mold.
Blow molding: involves inflating a heated thermoplastic preform inside a mold cavity, then blowing in compressed air to form the plastic to the mold. Once the plastic cools, the formed component is removed. Blow molding is frequently used to fabricate hollow parts such as containers for beverages, personal care products, cleaning supplies and more. Benefits of this process are that it is cost-effective and can be used to create shapes that cannot be achieved with injection molding.
Choosing the Right Material for Your Custom Plastic Parts
Ace Seal utilizes a wide range of plastic materials to fabricate custom plastic components. Each material carries different advantages and should be chosen based on your application requirements. Some key things to consider when choosing a plastic material include:
- Do you need a part this is rigid or flexible?
- Does your application involve exposure to extreme temperatures or variations in temperature?
- Will the plastic components be exposed or chemicals or other corrosive substances?
- Is this product intended for outdoor use or is degradation from UV exposure is a concern?
- Do you require a food-grade or medical-grade plastic material?
- Are there any industry regulations or requirements your finished product must adhere to?
Plastic Injection Molding Material Options
Ace Seal provides numerous material options for your custom plastic components. If you require a specific plastic material for your application and do not see it listed below, please contact us to discuss options.
- HDPE: provides a high strength-to-weight density ratio and resistance to a variety of solvents. HDPE is widely used for items such as plastic bottles, food storage containers, outdoor furniture, and piping.
- Polypropylene: a chemical-resistant material that provides toughness, elasticity, fatigue resistance and insulation. Commonly used for electronic components.
- PVC: a lightweight, yet strong plastic that often has plasticizers added to increase softness and flexibility. PVC is frequently used for construction, automotive and electronics applications, and in medical devices.
- ABS: a tough plastic that provides resistance to impact and high temperatures. It is one of the most commonly injection molded plastics used for 3D manufacturing and the fabrication of OEM parts.
- Acetal: is low friction, easily machinable and impact resistant. Acetal is often used for the fabrication of gears, electrical components, furniture hardware, and automotive components.
- Nylon 6 and Nylon 66: provides high tensile strength and elasticity and is resistant to chemicals and abrasion. These plastic materials are used for applications that require high mechanical strength, rigidity and stability. Common uses include automotive components, pipes and machine parts.
- PBT: a strong, stiff, high-performance plastic that provides dimensional stability and chemical resistance. It is used for electronic, electrical and automotive applications.
- Polycarbonate: a naturally transparent thermoplastic that can transmit light and withstand impact. This material is often used for windows, lighting fixtures, eyeglasses, medical devices and automotive components.
Contact Ace Seal for Custom Plastic Parts Manufacturing
Ace Seal is a global manufacturer of custom O-rings, seals, gaskets and other molded rubber & plastic components. Contact us today to learn more about plastic injection molding and other fabrication processes or request a quote your custom plastic components.
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