Injection Molding Factory in Thailand

Plastic injection molding in Thailand is a manufacturing process which produces molds via liquid injection. It is most commonly performed with thermoplastic polymers (i.e., Polypropylene, ABS, Polyethylene, Polystyrene). Plastic injection molding creates a high volume of consistent, high-quality units. When manufactured in large volume, injection molding has an extremely low cost per unit 

However, keep in mind that up-front costs for injection molding in Thailand tend to be high because of costs associated with design, testing, and tooling requirements (i.e., complexity, materials, accuracy, etc.); therefore it’s essential the design is right the first time.

One way to save costs is to combine different materials into the same part for greater utility with fewer assembly processes. With 2 shot injection molding, you can use a hard and a soft plastic to create a sealing edge and/or use two different colors. Similarly, insert molding allows a non-plastic component, such as a metal screw, to be incorporated into the design.

Since plastics are a primary component of many consumer products, and injection molding is one of the fastest ways to manufacture plastics. Injection molding has become the main choice to produce large quantities of products for various industries. But because of the high up-front cost there are several things that need to be taken into consideration.

Material in granular form is fed through a hopper into a heating barrel.The plastic is heated to a predetermined temperature depending on material and then driven by a large screw through the gate(s) and into the mold. Once the mold is filled, the screw will remain in place to apply pressure for the duration of a predetermined cooling time. Upon reaching this point, the screw is withdrawn, the mold opened, and the part ejected. Gates will either shear off automatically or be manually removed depending on mold types.

Molding condition means cylinder temperature, injection speed, mold temperature etc. set in an injection machine to obtain required products, and the number of combinations of these conditions are incalculable. Depending on the conditions selected, the appearances, dimensions, and mechanical properties of the molded products change considerably, therefore well-tried technology and experience are required to select the most suitable molding conditions.

Design is one of the most important parts of the production process because it’s the earliest opportunity to prevent expensive mistakes later on. There are many objectives to design for such as function, aesthetics, manufacturability, assembly, etc. The right design is one that accomplishes the required objectives to a suitable level, but it may take a lot of creativity and experience to get there.

For example having a uniform wall thickness whenever possible, and to gradually transition from one thickness to another when changes in thickness are unavoidable is a good way to avoid molding defects, some other design consideration such as avoiding corners that are 90° or less to prevent build up stress. Features that include large undercuts require experience to design, but can often add costs to the project.

For injection molding, molds are commonly made from these types of metals:

• Hardened steel: Typically the most expensive material to use for a mold, and generally the longest-lasting (which can drive down price per unit). This makes hardened steel a good material choice for products where multiple hundreds of thousands are to be produced.
• Pre-Hardened steel: Does not last as many cycles as hardened steel, and is less expensive to create.

Because tools are typically made out of steel or aluminum it can be difficult to make changes. If you want to add plastic to the part you can always make the tool cavity larger by cutting away steel or aluminum. But if you are trying to take away plastic you need to decrease the size of the tool cavity by adding  metal to it. This is extremely difficult and in many cases might mean needing to scrap the tool or part of the tool and start over. In other cases you might be able to weld metal into the cavity that is undesired. 

Since producing only one product per one shot is very inefficient, a mold is usually designed to have multiple cavities (calculate by estimating use quantity), connected with a runner so that multiple products can be made by one shot. 

Sprues and runners are side products that are produced when molded, these side products are sometimes discarded, but in other cases they are finely reground and reused as materials for molding. These materials are called reprocessed materials. Reprocessed materials are not solely used as materials for molding but usually used after blending with virgin pellets, since there is possibility of deterioration in various characteristics of the plastics because of the initial molding process. The maximum allowable limit for the ratio of reprocessed materials is about 30 %, otherwise reprocessed materials may spoil the original properties of the plastics used.

Our team has years of experience providing the best advice from product design to mold design and manufacturing. We can highlight potential design problems in customer’s design and avoid costly tooling modification that might occur after manufacture, saving cost and time. 

Our team has designed various types of products from house appliances to automotive and electronic parts. Whether it is conventional injection molding, double injection molding, or over-molding, we have done it all. We accept minimum productionSend us your product files, we will send you our best quote as soon as possible.

For more information on plastic injection molding in Thailand, please email psaechen@gmail.com , call 09-244-511-76 or click here to submit your enquiry.