6 Ideas to Reduce Your Injection Molding Costs

Producing high-quality parts while keeping costs minimal is a tricky balancing act.

Producing high-quality parts while keeping costs minimal is a tricky balancing act. However, significant cost savings are attainable in injection molding with a strategic approach to design and material choices. Injection molding solutions can improve productivity and quality by optimizing melt temperatures and screw designs. In this article, we’ll delve into six ideas to achieve this.

What is Injection Molding?

Injection molding is a widely used manufacturing process in which molten material, typically plastic, is injected into a mold to produce parts in high volumes.

Thanks to its ability to produce complex shapes with great precision, injection molding thrives in the mass production of parts, ranging from simple toys to intricate components in the automotive and aerospace industries.

While the cost per part can be pretty low, especially once order quantities get to the thousands, the upfront costs can be high due to the tooling costs related to the mold. The best time to reduce costs is in the design phase, and optimizing the performance of the injection molding machine is crucial for enhancing productivity and reducing cycle times.

Understanding Injection Molding Costs

Injection molding costs can be divided into several key components, each crucial to the overall expense of the process. Understanding these costs is essential for optimizing the process and achieving significant cost savings.

Tooling Costs: One of the most substantial investments in injection molding is the cost of creating the mold. This includes the design, engineering, and manufacturing of the mold, which can be a significant portion of the overall budget. However, you can mitigate these costs by focusing on efficient mold design and considering long-term use.

Material Costs: The type and quantity of material used in the injection molding process can greatly influence the overall cost. Selecting the right material that meets the functional requirements of the part while being cost-effective is key. Staying updated on material advancements can also present opportunities for cost savings.

Labour Costs: Labor costs encompass the expenses related to the workforce involved in the injection moulding process. This includes machine operators, quality control personnel, and maintenance staff. Streamlining operations and investing in automation can help reduce labor costs.

Overhead Costs include energy consumption, maintenance, and other operational expenses. Efficient energy use, regular maintenance, and production process optimisation can help control these costs.

By understanding and managing these cost components, you can make informed decisions that lead to a more cost-effective injection molding process.

Optimize Wall Thickness

One of the foundational principles in injection molding design is ensuring a uniform wall thickness. Doing this ensures even cooling, minimizes warping, and reduces material usage.

When parts cool unevenly, it can lead to internal stresses, sink marks, and other defects. By keeping walls uniform and as thin as feasible without compromising the part’s function, you can save on material costs and reduce the risk of defects.

Additionally, the design of injection molds plays a crucial role in optimizing heat transfer and energy consumption. Proper mold design, including the sizing and positioning of cooling passages, is essential for enhancing energy efficiency and improving product quality.

Minimize Undercuts 

Sometimes, undercuts – such as holes, depressions, or protrusions – are essential for the part’s function or aesthetics.

Otherwise, it would be best if you eliminated undercuts. These complicate molding and require unique mechanisms that drive up tooling costs. These mechanisms might include sliding parts or ejection pins to ensure the safe removal of the finished part.

By avoiding unnecessary undercuts or redesigning parts to eliminate them, molding becomes more streamlined and less expensive. Additionally, addressing insufficient draft angles during the design for manufacturability analysis can help identify and rectify potential issues, leading to improved part designs before finalization.

Use a Family Mold to Improve Production Efficiency

The molds can lead to high tooling costs, so why not maximize resources with a family mold?

Family molds can be a cost-effective solution for producing multiple parts in a single cycle. Instead of investing in separate molds for each part, a family mold produces multiple parts in a single cycle.

However, this approach requires meticulous design to ensure even filling and cooling for each part in the mold. The rewards are well worth the extra effort if it’s done right.

Invest in Multi-cavity Molds for High Volumes to Reduce Tooling Costs

Multi-cavity molds can offer considerable cost savings for projects demanding high production runs.

Unlike single-cavity molds, which only produce one part at a time, multi-cavity molds can create multiple identical parts simultaneously. Though the initial investment is steeper than that of single-cavity molds, the per-part production cost is drastically reduced, making it a sound long-term investment for large-scale production.

Consider Draft Angles

Including a slight taper or draft angle on the surfaces of the molded part can significantly ease the ejection process.

This small design consideration can reduce mold wear and tear, decrease cycle time, and minimize the risk of part defects or damage during ejection.

Choose the Right Material

Materials often constitute a significant portion of the production cost in injection molding.

While some projects require specific, high-grade materials, others might achieve the same functional goals with more economical alternatives. Engaging with product partners and staying updated on the latest in material science can present cost-effective options without compromising quality. Additionally, optimizing melt temperature plays a critical role in enhancing cycle time, part quality, and energy efficiency.

Efficient Processing Techniques

Efficient processing techniques are vital for reducing injection molding costs and enhancing production efficiency. Implementing these techniques can improve part quality and lower overall expenses.

Optimize the Injection Molding Cycle: Adjusting the temperature, pressure, and cooling time during the injection molding cycle can significantly impact the final product. Fine-tuning these parameters ensures that parts are produced with minimal defects and material waste, leading to cost savings.

Core Cavity Design: A core cavity design allows for the production of complex parts with minimal material waste. This design approach reduces material costs and enhances the structural integrity of the parts.

Energy-Saving Technologies: Significant energy-saving technologies, such as all-electric injection molding machines, can drastically reduce energy consumption. These machines offer precise control over the molding process, leading to improved efficiency and lower energy costs.

By incorporating these efficient processing techniques, you can achieve a more streamlined and cost-effective injection molding process.

Machinery and Technology

The right machinery and technology can significantly reduce injection molding costs and production efficiency. Investing in advanced equipment and innovative technologies can lead to substantial cost savings and improved part quality.

Advanced Injection Molding Machines: Machines with features like precise temperature control and high-pressure injection can enhance part quality and reduce material waste. These advanced machines ensure consistent production and minimize defects, leading to cost savings.

Inline Compounding and Vented Extrusion: Technologies such as inline compounding and vented extrusion can help reduce material costs and improve production efficiency. These methods allow for better material utilization and reduce the need for additional processing steps.

In-Mold Technologies: New technologies like in-mold welding and assembly can reduce labor costs and improve part quality. These techniques integrate additional processes into the molding cycle, streamlining production and reducing the need for post-molding operations.

Leveraging the latest machinery and technology can enhance production efficiency, reduce material and labor costs, and achieve significant cost savings in your injection molding process.

Get Started with Injection Molding

Balancing quality with cost-efficiency in injection molding might seem daunting, but these strategies can help you effectively navigate the process.

At MakerVerse, we’re happy to provide just that. Work with us for the expert guidance you need to maximize injection molding.