Choosing the right molding method can greatly impact the cost and quality of your product. With several types of custom plastic molding processes available, it can be overwhelming to determine which one best suits your needs. Whether you’re producing high-volume products or intricate, low-volume parts, understanding the differences between these custom plastic molding techniques can help you make an informed decision for your business.
In this guide, we’ll walk you through the most common types of custom plastic molding. We’ll highlight their advantages, ideal applications, and give you tips for selecting the right process. Let’s dive in.
Injection Molding
Injection molding involves producing parts by injecting a molten polymer into a mold. The polymer is fed into a heated barrel, mixed, and injected into the mold cavity, where it cools and hardens into that shape. This manufacturing method is widely used for a variety of items, from toys to electronics and beyond.
Blow Molding
Blow molding works by forcing plastic against a mold wall through air pressure. This process is usually used to create containers like soda bottles and milk jugs, along with other hollow products.
Rotational Molding
Rotational molding is a highly specialized manufacturing method that’s ideal for creating everything from storage tanks to playground equipment. In this process, a polymer is heated inside of a mold, which is then spun around two perpendicular axes. The polymer coats the inside of the mold, which creates a tight-tolerance, hollow part.
Extrusion
Extrusion is a process that shapes a material into a specific form by forcing it through a die. This method is commonly used to create objects with a fixed cross-sectional profile, like tubes.
Thermoforming
Thermoforming is the final most common plastic manufacturing method. It involves heating a plastic sheet, and then laying it over a mold. From there, it’s allowed to cool, taking on the form of the mold. This method is most commonly used to create items like clamshell packaging.
Factors to Consider When Choosing a Molding Process
Part Size and Complexity
Part size and complexity play a huge role in which production process you should choose. Complex or intricate designs may require advanced techniques like injection molding. Simpler shapes may be produced with processes like extrusion or rotational molding.
If you have a large hollow part, you’ll likely want to choose a manufacturing method like rotational molding. This process will be most efficient and get you to market faster.
Production Volume
Some processes are better suited for high-volume production than others. Injection molding and blow molding may be better for higher volumes while thermoforming will be better for lower volumes. Methods like injection molding often offer faster cycle times, which allows more parts to be made more quickly.
However, it’s important to note that other manufacturing methods have been shortening cycle times. For example, at GVL Poly we have a Leonardo SMART Molding Machine that offers unparalleled cycle times and other advantages. In some cases, this can make rotational molding a competitive choice where it hadn’t been before.
Tooling Costs and Lead Times
Tooling costs and lead times can significantly impact both the initial investment and the time required to bring a product to market. Typically, injection molding will have the highest tooling costs because of the need for precise, durable molds. Processes like rotational molding will have lower tooling costs, as they are simpler in design.
Additionally, injection molding will have longer lead times because the mold design is so intricate. Other processes like rotational molding will allow you to get to market faster because of the mold simplicity.
Work with GVL Poly for Your Rotomolding Needs
If you have questions about what manufacturing process is right for you, we can help. For over 30 years, we’ve been creating the best rotomolded parts for our customers, ensuring they meet high expectations. Over the years, we’ve helped countless businesses get the right fit for their organization. We’d be honored to help you, too.
At GVL Poly, we can help you from start to finish. Our in-house team can cover everything from design and rapid prototyping to fabrication and logistics. All of our services are backed by experienced machine operators, engineers, designers, tool builders, and other professionals. When you work with us, you can be sure you’re getting the best products possible.
Let’s Get Started
Are you ready to start your next rotomolding project? We’d love to help and answer any questions you may have. Get in touch with us here.
