• Injection molding: production and processing

    Injection molding: production and processing

Our services as a plastic injection molding manufacturer

Materials

Materials

Thermoplastics and elastomers as single component and mulitcomponent parts
Part sizes

Part sizes

from 1g to 4,9kg
Closing force

Closing force

30t to 1100t
Automations

Automations

fully automated robot handling systems fully automated subsequent processing
Subsequent processing

Subsequent processing

Printing, embossing, welding and Pressed-in parts
Sampling

Sampling

We carry out all sampling for new project starts in-house and qualify them professionally.

Injection molding at Plastro Mayer: from the injection mold to production

Plastic injection molding, also known as injection moulding, is a process for manufacturing high-quality plastic parts. From tooling to part production, Plastro Mayer offers an accurate and efficient manufacturing solution. Our customized injection moulding tools and our precisely moulded plastic parts of the highest quality have made us a leading and reliable plastic injection moulding manufacturer for many years.

The injection molding process consists of several steps:

  1. tool preparation: first, the injection mold is prepared in the tool shop with cleaning and insertion into the injection molding machine. The appropriate parameters such as temperature and pressure are then set.
  2. material melting: The thermoplastic is melted in a heated cylinder.
  3. injection phase: Under high pressure, the molten material is injected into the hollow mold (cavity) of the tool via the injection unit. It is important that the material fills all areas of the mold and that no air pockets are formed.
  4. cooling phase and solidification: During this phase, the material cools and solidifies, forming the final part. The cooling time is a critical factor for the cycle time and the quality of the final product.
  5. mold opening and part removal: The mold is opened and the finished part is removed. This can be done manually or automatically.
  6. post-processing: In many cases, the molded parts require post-processing after injection molding. This can include the removal of sprues, grinding, painting or other surface treatments.
  7. re-injection: The process starts all over again.

Injection molding can be carried out using single-component injection molding or multi-component injection molding. Both processes are ideal for the production of large series of plastic parts. However, the production of molded parts in small batches is also no problem for us. With our modern injection molding machines, we guarantee a precise, efficient and automated process in every case.

Plastro Mayer is a full-service provider with the business areas of injection molding, cables, device assembly and toolmaking, offering everything to do with plastic injection molding and production from a single source. With us, you also have the option of using the services of individual business units.

We would be happy to receive your inquiries so that we can jointly develop an individual injection-molded plastic solution for the production of your plastic parts. We look forward to convincing you of our services. You can also take a look at the list of our numerous references.

Get in touch with our plastic injection molding experts today!

An excerpt of our customers as injection moulded parts manufacturers

 

 

The right plastic: injection molding to suit your order

As an experienced plastic injection molding manufacturer, we have a broad and in-depth knowledge of a wide range of industries. In our injection molding production, we process various high-quality materials in all colors and strengths. The following main material groups are available to you:

  • Thermoplastics
  • elastomers

We have a large selection of thermoplastics in stock and process them using single-component and multi-component injection molding. These thermoplastics include, among others

  • Polyamide (PA)
  • Polystyrene (PS)
  • Polyethylene (PE)
  • Polypropylene (PP)
  • Polymethyl methacrylate (PMMA)
  • Acrylonitrile butadiene styrene (ABS)
  • Polycarbonate (PC)
  • Polyoxymethylene (POM)

In addition, we are also able to use glass fiber reinforced material, glass bead material, material with added minerals, carbon fibers or wood fibers. Our range also includes heat-resistant, fire-protected, food-safe and drinking water-approved materials. We also offer rubber molded parts made of elastomer (NR) and plastic injection molded parts made of bioplastic or biopolymer, which is made from renewable raw materials.

We process the materials you require in our injection molding machines. If you are not sure which material is best suited for your required molded parts, simply contact our injection molding experts. We will help you select the right material and, thanks to our many years of experience in injection molding, can provide you with expert advice on the suitability of your component. On request, we can also sample your molded part in various materials in order to support you with regard to possible test procedures and in selecting the best solution.

An excerpt of our capabilities in plastic injection molding

Medical and laboratory technology

Medical and laboratory technology requires specific components made from high-quality plastic injection molding. Every customer has individual requirements for injection molding and plastics technology.

Filter and water technology

Sophisticated injection molded parts with special requirements for pressure load changes, for example, can be found in filter and water technology. These include complex filter parts with threads, pressure pipes with pressed-in brass bushes and components with tight tolerances.

Household

High standards apply to plastic injection molded parts in the household goods industry. These are frequently used due to their versatility, durability, lightness, heat resistance, ease of molding and resistance to moisture and chemicals.

Chair industry

One advantage of plastic parts for chair manufacturing is their strength and individual formability. They are often used to manufacture various components, including seat shells, backrests, armrests and leg braces.

  • Backrest frame + seat shell

    Backrest frame and seat shell

    frame. approx. 1200g, supporting part for net covering, seat shell: approx. 1430g, high mechanical load, low distortion
    Chair industry...
  • Backrest with seat shell black

    Backrest with seat shell black

    for office chair, low distortion, good surface appearance, structured
    Chair industry...
  • Backrest with seat shell white

    Backrest with seat shell white

    high gloss, with ultrasonic welded thread inserts
    Chair industry...
  • Foot crosses swivel chairs

    Foot crosses swivel chairs

    supporting part for swivel chair, high impact strength, low warpage, surface with grain, 1500g (PA6 glass fiber reinforced)
    Chair industry...

Automotive

The automotive industry also relies on high-quality plastic injection molding. This is used in a wide variety of areas to improve both the performance and aesthetics of vehicles. Plastics allow manufacturers to create complex shapes and designs through injection molding.

Lamp parts

The main advantage of molded parts produced by injection molding for the lighting industry is their versatility and heat resistance. As they can be produced in almost any desired shape, this allows many possibilities for creative designs.

  • Final part

    Final part

    heat and shape resistant, textured surefaces, high accuracy of fit
    Lighting industry...

Electric tools

The use of injection-molded plastic parts for the production of power tools has increased significantly in recent years. Among other things, this is due to the decisive advantage that injection-molded plastic is significantly lighter than metal despite its durable strength.

  • End part printed

    2K part

    printing directly on maschine fully automated
    Power tools...

Two component parts

Two-component injection molding is a process used to produce components with different material properties or colors. Two different plastics are joined together in a single injection molding process without additional adhesives or weld seams. The result is increased stability and product quality.

Get in touch with our experts in plastic injection molding manufacturing ...

Injection molding contact

Jürgen Hack

Sales manager injection molding and devices
We are your partner if you are looking for a plastic injection molding manufacturer. We will support you in manufacturing your components with the appropriate mold. We will be happy to make you an appropriate offer and find the right solution for your project together with you. For this purpose, please send us your inquiry with indication of the corresponding annual quantity and the desired material via our contact form. If possible, please attach drawings and 3D data in STEP or IGES format to your inquiry. Our expert will then contact you for further information.

Injection molding: the most important facts at a glance

What processes and material combinations are possible in plastic injection molding to produce 2K parts?
There are various ways to produce a plastic part from several materials in plastic injection molding. For example, this can be achieved using a rotary table tool or a transfer tool. Here, the first material is used in the first injection cycle of the injection unit (usually the hard component), then the plastic part is transferred either with a handling system or operating personnel (in the case of a transfer mold). Alternatively, the mold is rotated into a new position (rotary table mold). The second material (usually the soft component) is then injected into the mold in the next injection cycle. These processes are used for handle housings, battery housings, displays, etc. Many materials can be combined, but adhesion must be ensured at all times. In addition to a single hard component or soft component, a combination of two hard components is also possible. This allows different colors to be combined in one molded part. Hard and soft combinations are often used for housing parts that are to contain a seal. Here, for example, a soft component made of TPE can be injection-molded onto the hard component made of ABS. Our experts will also be happy to help you find the optimum solution for your 2K part.
What storage options does Plastro Mayer offer for storing injection-molded plastic parts until they are needed?
We adapt to your wishes and possibilities for the storage of produced plastic injection molded parts. We have a large finished goods warehouse in Trochtelfingen, where we are happy to store the injection molded parts for you until you need them.
What needs to be considered when designing parts that are to be manufactured using plastic injection molding?
The wall thicknesses of injection molded parts should be as thick as necessary but as thin as possible. Although plastics are light and inexpensive, the aim is to achieve maximum cost and weight savings. The larger the volume of molten plastic, the more likely it is that air pockets, the dreaded blowholes, will form. Plastics are poor heat conductors and have a high thermal expansion. On the outside of the mold, the component cools down quickly (solidifies) while it is still hot on the inside. The inside only cools down gradually - this makes the material want to contract. The larger this internal volume is, the greater the distortion of the component. The aim should be to distribute the mass evenly. Seams should be cleverly positioned and transitions rounded off. Furthermore, you should chamfer the surfaces for better demolding (introduce demolding chamfers). The staff in our in-house technology and design department will of course be happy to help you with the design. They have the necessary know-how in this area and can support you in planning your injection molded parts.
What component optimization options can Plastro Mayer offer for plastic injection moulding?
There are various options available to us for optimizing your plastic injection moulded part. Internally, we can offer you the support of our engineering and design department. Our employees use a moldflow analysis to examine various aspects of a component, such as shrinkage or uniform filling of the mold. This analysis enables us to identify weak points in the geometry of your molded part or the mold design and eliminate them before the injection mold is created. To carry out a moldflow analysis for your injection-moulded part, all we need is the CAD data of the component and the material you wish to use. We can also carry out the analysis for several materials if you have not yet made a decision. To optimize the distribution system or cooling, we also offer you further warpage calculations, for which we have been working with an external partner for many years. A 3D printer is also available to print out a tangible prototype for you shortly. Our experts will be happy to answer any questions you may have.
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