How to Scale High Volume Injection Molding Smoothly?

Plastic injection molding is one of the ancient high volume manufacturing methods. High volume injection molding is a specialized service that offers high-quality plastic parts in large quantities (up to millions in one month). Scaling up a new product into high volume manufacturing can be one of the rewarding and also challenging stages of the development life cycle.

What you decide during this time will pose a huge impact on all aspects of a product – from manufacturing control to tooling to user documentation to packaging. In fact, the problems that occur during the production stage may be costly to resolve. Thus, it is vital to create a robust plan before you plunge in.

STEPS:

Identify your Quantity

Injection molding company will usually require you to offer estimated yearly units for the first-run production. Thus make sure your plan should include estimates for first, second, and third-year units.

Research Your Options Well

Correct estimates will help you to make the correct decision regarding manufacturing and vendor. Just note every method has its own pros and cons. Thus, the best choice will depend on your specific application.

Design Your Product for High Volume

Make sure your 3D models are built using high volume injection molding. Thus includes creating accurate draft angles that allow plastic parts to be quickly eliminated from the mold. So you need to ensure that you have built plastic components with uniform wall thicknesses. It is because areas with thin wall usually cool fast than regions with thick walls.

Understand Manufacturing Processes Involved

Once you have chosen your manufacturing method, make sure the best injection molding Company understands the method well. Also, make yourself familiar with process limitations, complex manufacturing tolerances, and industry jargon. Thus, it is vital to ask the right questions to your agency.

Engage Your Supplier in the work

Existing prototype and data help the supplier to understand your product at a much faster. This will also help your high volume injection molding vendor to determine potential manufacturing issues with your design and enhancements.

Speak with Multiple Vendors about your Product

Take assistance from multiple reputed high volume injection molding companies to get molding services at a decent price. If possible, get feedback from them. It is because they might suggest something that will help you to make the incredible design.

Craft and Test Final Prototype

As your scale into high volume manufacturing, you should have full confidence in your product design. Some of the vendors offer high-quality prototypes that are made using techniques like room temperature vulcanized molding. Just note that silicone mold can usually be used for near about 100 castings. Thus, it is great for the short-run production of plastic parts.

Include your Resources in Discussions about Tooling

Just remember that high volume injection molding method may pose a significant effect on the final look of your product. Thus, make sure you plan accordingly during the prototype phase. Ask your supplier about surface finishes that can be applied to the plastic mold to fix common issues.

Reduce Plastic Waste

When you deliver your parts with sufficient geometrical variance, it is possible that your design falls out of specification. Prevent this costly mistake by specifying your design so that any potential changes in dimensions of your product would not involve any additional material.

Implement your Plan

Converting your product into a high volume product may require changes to your existing business techniques to ensure that the transition goes smoothly. Research and implement your method well to make your product successful. Also, make vital changes if necessary.