Plastic Injection Molding
What is large tonnage molding?
Large tonnage injection molding is the same process as traditional high-pressure injection molding, but for larger parts. Our largest machine is an 8,000-ton machine with up to 13’ x 13’ platens to make extremely large parts, with various sizes, shapes, and depths that are only possible with slower, potentially less-accurate (out-of-tolerance) processes.
Parts can weigh up to 325 pounds
Part size up to 160” x 114” or 156” x 118” (at a variety of depths)
Perfect for parts once only possible with sheet metal, fiberglass, rotational molding, or vacuum forming
Production possible in large quantities via single-cavity or multiple-cavity tools
The production of large plastic parts is the biggest benefit of this plastic molding method. Other forms of plastic molding, while effective, simply cannot match the size, scale, or design requirements offered by large tonnage molding.
An example – let’s imagine that your company produces plastic garden tool sheds. Most parts have been traditionally made using one or a combination of vacuum forming, blow molding, or rotational molding processes. These processes required parts to be made one at a time, often with expensive secondary requirements.
Using large tonnage injection molding, the process is streamlined and allows for the shed walls & roof to be produced in one machine cycle, either as one piece, or multiple pieces, saving machine time, labor, & material costs.
In addition to large part production, the big platen size is also useful for producing many smaller parts at one time – i.e. multiple irrigation channels & grates. With faster cycle times than other methods of plastic molding, large tonnage production enables quicker turnaround times of large quantities of small or large plastic parts.
Our large plastic part molding occurs at two of the most comprehensive plants (across three separate campuses) in the United States. The Midwest facility is currently completing a major expansion project, including adding storage space for the large parts, making it one of the largest facilities of its kind in the country.
All locations offer state-of-the-art equipment and offer the following capabilities:
- All presses are robot-equipped and served by overhead cranes up to 125-ton capacity
- Ample truck and rail access at both locations
- Complete and independent systems for each auxiliary system minimize downtime, including tower water, chiller water, nitrogen, and air.
- A total of 32 independent “Weight Scale, Six Component Blender/Loaders” are used for material delivery, each with its own vacuum pump.
- x36 raw material storage silos with a total capacity of over 4.5 million pounds.
Our manufacturing plants offer the following molding machines:
- 85 Ton Cincinnati-Milacron
- 375 Ton Cincinnati Milacron
- 500 Ton Cincinnati Milacron
- 725 Ton Cincinnati-Milacron
- 1300 Ton Cincinnati-Milacron
- 2300 Ton Cincinnati-Milacron
- 2600 Ton Cincinnati-Milacron
- 3000 Ton Cincinnati-Milacron
- 6750 Ton Cincinnati-Milacron
- 8000 Ton Cincinnati-Milacron
Nothing Short of Precision Injection Molding
Injection molding is a manufacturing process used to produce parts by injecting molten material, typically plastic, into a mold cavity for shaping, then solidifying it into a final product – it also happens to be our expertise.
As one of the most popular plastic manufacturing processes, injection molding is widely used for different applications across diverse markets. Backed by decades of experience, AdvancTEK provides injection molding solutions of varying sizes and volumes for industries like:
- Industrial
- Medical
- Battery an energy storage
- Telecommunications
- Powersports and recreation
- Construction and agriculture
We also specialize in producing large plastic parts for your bigger projects.
Injection Molding Explained
Injection molding is a great option for higher-volume plastic molding projects. Melted plastic resin is injected into a mold to produce high-quality and often complex components. Parts often have “A” and “B” side design features that are functional, structural, or aesthetic.There are several benefits to injection molding, but the suitability of this process is entirely dependent on the details of project
With its ability to mold B-side features, achieve tight tolerances, and be produced in a wide range of basic to highly engineered materials and colors, injection molding offers a great deal of part design freedom, which can help designers solve a variety of challenges for their products.
Advantages
Disadvantages
Advantages
- High production rates – The speed and efficiency of the process are ideal for large-quantity orders. We are able to produce parts quickly with very little variation.
- Speed – Plastic injection molding manufacturers produce a large quantity of parts per hour, and cycle times are significantly faster than processes like thermoforming or RIM.
- Repeatability – The plastic used in injection molding is forced into the mold under immense pressure. Due to this, a large amount of detail and complexity can be incorporated into these parts. Action can be incorporated into the tool design to allow for die lock features to be designed into the part. Plus, parts can be easily replicated, over and over again.
- Cost-effectiveness – Plastic injection molding solutions tend to have a lower price per unit than many other plastic manufacturing processes.
- Minimal waste production – Injection molding has a very low scrap rate, producing only a small amount of scrap compared to other processes. Additionally, much of the material is recyclable, making it an environmentally friendly option for many industries.
- Lightweight – Modern thermoplastics used in injection molding are inherently lighter than metals, yet can provide comparable strength and durability. Materials such as ABS, nylon, and polycarbonate are engineered to be lightweight while meeting demanding structural requirement.
Disadvantages
- High initial tooling costs make this process more suitable for high-volume production runs
Plastic Injection Molding Myths
There are several misconceptions surrounding large part molding. One common mistake is oversimplifying the required tonnage. Factors like material type, wall thickness, and gating play crucial roles in determining the size of the machine needed. Our custom plastic injection molding company conducts detailed mold flow analysis and simulations to optimize each project, ensuring the most efficient use of equipment.
Another often overlooked aspect is the cost and logistics of shipping large molds. Moving these molds requires careful planning, the right type of trailer, and cranes for loading and unloading. R&D’s extensive experience and logistics capabilities enable effective management of these challenges, which is why we are among the best plastic injection molding manufacturers to work with.
If injection molding doesn’t sound like the right fit for you, explore our other manufacturing processes, reaction injection molding (RIM) and thermoforming.
Materials Used for Injection Molding
The best material for your product will depend on its desired properties and application, budget constraints, and environmental factors. Weeding through all the hundreds of material options can be daunting, but that’s what AdvancTEK is here for!
Our team provides expert advice on material selection based on these considerations. AdvancTEK maintains an inventory of several different plastics ready for your next injection molding project, including:
- Polypropylene (PP)
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Thermoplastic Polyolefin (TPO)
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Acrylonitrile Butadiene Styrene (ABS)
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Polycarbonate and Acrylonitrile Butadiene Styrene (PC/ABS)
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Acrylonitrile Styrene Acrylate (ASA)
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Nylon
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Flexible Polyvinyl Chloride (PVC)
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Polyethylene (PE)
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High-density Polyethylene (HDPE)
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Glass-filled or mineral-filled varieties
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UL94 V-0 rated materials
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Chemical foaming agents
FAQs About Our Abilities as a Custom Injection Molding Manufacturer
Between our two injection molding sites, AdvancTEK has 65T – 3500T molding, with the largest machines located in Saltillo, Mexico. One of our 3500T machines also has a shot size of 70 lb, which is one of the largest in North America.
AdvancTEK is IATF 16949 and ISO 14001 certified. As part of our APQP process, we also collaborate with customers early and often to define CSRs (customer specific requirements) to ensure we are meeting all customer requirements.
Yes! We have a team of design, product, process, and manufacturing engineers who work with customers at various stages of their development cycle. We offer full design and development services, in addition to DFM (design for manufacturability) and product design recommendations. As part of any proposal development, we will identify initial part design issues that may affect manufacturability, cost, quality, or other key items.
Yes! We are a custom manufacturer and are very accustomed to both commodity and highly engineered grades of materials. To name a few, we currently use PP, TPO, HDPE, ASA, PC-ABS, and Nylon, in addition to glass- or mineral-filled materials, chemically foamed materials, and gas-assisted materials.
Our sales team would be happy to connect with you. Use one of the contact forms on this website or call the number at the top of the page. Each quote is custom-tailored to meet your specific requirements.
Large Part Injection Molding
Large-part injection molding is a manufacturing process for producing large parts in high volumes. It is commonly utilized in mass production processes in which the same part is recreated thousands or even millions of times in succession. The main benefit of injection molding is the ability to produce parts en masse and cost-effectively.
During the injection molding process, hydraulic pressures exceeding 20,000 psi are utilized to push the two halves of the mold apart. Typically, injection molding machines are rated by “clamping force” in tonnage. “Clamping force” refers to the force used to clamp the two halves of the mold together. Notably, molded parts with a larger surface area require greater tonnage and vice versa. Usually, the machines rated as “large tonnage” come with 500 or more tons of clamping force.
What Makes Plastic Injection Molding for Large Parts Different From the Standard Plastic Injection?
Plastic injection molding presses can be rated or classified depending on tonnage or clamping pressure and force. Presses run in sizes from as few as five tons of clamping pressure to as high as 3,000 tons of clamping pressure. Notably, the higher the press ton rating, the larger the specific plastic injection molding machine.
A large-tonnage injection molding machine naturally requires a massive amount of resources. Large-tonnage machines require a footprint of approximately 40′ x 15′ x 15′ and cost anywhere from $250,000 to over $1MM. The injection molds processed with these machines exceed 10,000 pounds and need special lifting equipment.
In essence, the big difference between plastic injection molding machines for a large part and those for standard plastic injections is that large machines typically run more complex parts. They are also more expensive to acquire while requiring massive space for staging, packaging, and storing parts. This is the main reason why fewer companies choose to offer machines greater than 500 tons. This also explains why these machines are unique and scarcer than standard injection molding machines.
How to Determine If Your Part Requires a Large-Ton Machine
There are several factors to consider when deciding on the size of the press. These include the size of the part, the polymer used, and the safety factor. Specifically, the safety factor refers to an extra numerical percentage buffer added to the calculation to help eliminate the risk of defects on the final product. Experts recommend adding 10% to allow for the safety factor.
The general rule of thumb for measuring the amount of tonnage needed for any given plastic under production is 2-8 tons per square inch. This means that a 10″ x 10″ part (100 square inches x 2 tons/sq. in.) will require 200 tons. Remember, the larger the part, the more clamp force is needed to hold the two halves of the mold together during the injection process.
Large-Part Injection Molding Capabilities at Lerner Molded Plastics
As the leading Ohio plastic parts manufacturer, Lerner Molded Plastics is committed to providing all our clients with precision, custom plastic injection molding services that deliver premium quality components. We leverage our ISO 9001 2015-certified facility to offer custom molded plastic parts with diverse materials. We can produce high-volume small and large parts with shot sizes ranging from 3 to 600 ounces. Our advanced plastic molding equipment boasts unmatched pressure clamping force, ranging from 30-3,000 tons and up to 64 cavities. We also provide large-part rotational molding, blow molding, and thermoforming with custom coloring capabilities. Some of the plastic materials that we offer for large-part injection molding include:
- Polypropylene (PP) ○ Polystyrene (PS)
- High-Density Polyethylene (HDPE)
- ABS
- Nylon
- Acetal
- Polyester (PET / PETG) ○ Acrylic
- Polycarbonate (PE)
Our experts are committed to helping you create a product that offers maximum quality at lower production costs. We combine the power of cutting-edge infrastructure, innovation, and experience to produce high-quality and cost-effective parts that meet your specific needs. We also offer a full line of value-added services to complete your manufacturing requirements. To learn more about our custom plastic injection molding services, contact us today or request a quote.
