Multi-material injection molding, also known as overmolding, allows for combining different materials into a single part, providing enhanced functionality, such as a hard substrate overmolded with a soft rubber grip for improved user comfort. For more information, see our Engineered Resins Material Guide.Why Choose PMC? Unfortunately, there’s a surplus of button-pushing plastic injection molders in this industry. When there’s a process problem or a part defect, these plastic molding operators attempt to resolve the issue by changing the cycle process with configuration variations. Part specifications you’ll want to detail in your plastic injection mold design include:Part SizePart GeometryWall ThicknessDimensional TolerancesNumber of CavitiesPresence of Sharp Corners or RibsPresence of Holes and CoresApplicable InsertsElectrical RequirementsApproximate Part Life ExpectancyOther Needed Secondary OptionsStrength

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The importance of collaborative design efforts in injection molding cannot be underestimated. Cross-functional teams working together can address potential production challenges early in the design phase, resulting in more efficient and cost-effective processes. Cooling channels within the mold need to be efficiently designed to achieve uniform heat dissipation, reducing cycle times and improving part quality. As experienced plastic molders, our highly knowledgeable team understands the critical plastic injection molded part design considerations to create high quality plastic parts. Our plastic mold design consultations have renewed multiple projects after our engineers diagnosed and provided solutions for correction of improper mold design. Draft angles are incorporated into mold designs to facilitate part ejection by reducing friction between the part and the mold walls.

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Part cooling is the longest phase in the injection molding cycle, and reducing cooling time through optimized mold design or advanced cooling technologies can significantly increase production rates and reduce per-part costs. These plastic injection molders use what are called commodity resins, such as polyethylene and polypropylene. These are common resins that are not engineered for extreme conditions. Thermoplastic injection molding is widely used due to the material's recyclability, where leftover or scrap parts can be reground and remelted, reducing material waste and supporting sustainability in the manufacturing process. Injection molded plastic gears are now being used in electronic & electrical appliances, industrial equipment, the medical industry, the automotive industry & many more. The cooling phase in injection molding is the most time-consuming step, as the molded part needs to solidify fully before ejection. Optimizing cooling channels and mold materials can significantly reduce cycle times and improve production efficiency.