Thick Wall Injection Molding vs. Structural Foam: What’s Best for Large Plastic Components?

There are multiple different manufacturing methods available to create large plastic components. Depending on the specs of your project, thick wall injection molding or structural foam molding might be two viable options for your team to consider.

Each manufacturing operation contains their own sets of benefits, best applications, and certainly their own process. But, how to tell which is right for your product?

Port Erie Plastics pits these two manufacturing operations against one another in the pursuit to find out which is best for large plastic component manufacturing.

Best Uses for Each Manufacturing Process

Thick wall injection molding and structural foam molding each are capable of creating large plastic components, but these two manufacturing operations should be used with specific considerations and project criteria in mind.

Thick Wall Injection Molding

Consider using thick wall injection molding for projects where wall thickness is more moderate and manageable rather than extreme. When parts need tight dimensional control and high, easy repeatable actions and better scalability, thick wall injection molding should be the go-to. Traditional injection molding already lends itself to high-volume capabilities, and even though the wall thickness might be larger than normal, the process still lends itself to high-volume manufacturing capabilities, just with a longer cycle time.

Structural Foam Molding

When parts are large, extremely thick, or highly ribbed, this is where the conversation should shift toward structural foam molding. The process uses low pressure and a cellular core with solid skin to create parts where stiffness to weight ratio is improved. Additionally, sink marks and warpage are greatly reduced because of the low pressure.

Structural foam molding better supports large molds and the materials required for tooling can be much more cost-effective since cavity pressures in the processes are lower.

Tradeoffs

Choosing one manufacturing process over the other means not having the capabilities of the passed over manufacturing operation. If your team decides on structural foam molding, you are forgoing manufacturing of complex designs, tight tolerances, and smoother aesthetics.

If the choice is thick wall injection molding, you’re passing on lower clamping forces, lower tooling costs, better stiffness, and overall lighter parts.

Large Component Focus

In general, large plastic components are going to be more favorable for structural foam molding to perform the manufacturing. This stems from the cost-effectiveness of the process and its ability to handle large component manufacturing with relative ease. While it’s more favorable, if parts do feature complex designs and intricate shapes or tight tolerances, the heavier costs of injection molding are likely to be endured.

Achieve High-Quality Thick Wall Injection Molding Services and Partner with Port Erie Plastics Today

Port Erie Plastics has operated as a plastic processing manufacturer equipped with multiple capabilities for over 70 years. When we opened for business in 1953, we did so with a single injection molding machine. Since then, we’ve turned that single machine into 90 with maximum clamping forces of 1,650 tons, shot sizes up to 470 ounces, and parts weighing as much as 24 pounds.

Of course, injection molding isn’t the only manufacturing operation we perform in our Harborcreek, Pennsylvania, facility. If your program isn’t a match for injection molding, we also perform structural foam molding operations, and our engineering team can work with you to transform your design from injection to structural foam molding with ease.

Thinking about starting a thick wall injection molding program? Contact the experts at Port Erie Plastics today.

A Guide to Large Part Injection Molding for Heavy-Duty Plastic Housings and Enclosures

Large part injection molding operations are commonly performed by contract manufacturers for specialized programs that need high-volume components at a cost-effective rate. Heavy-duty plastic housings and enclosures are just two examples of the numerous large parts that can be created through injection molding.

Typically, when injection molding is discussed, most companies think the manufacturing process can only do smaller parts. While it’s true that it might be a little easier for a program to feature smaller components, large part injection molding remains not only a possibility, but a capability.

Port Erie Plastics’ guide on large part injection molding services catered toward heavy-duty housings and enclosures provides design considerations, material selection advice, best tooling practices, and more.

Design Considerations

The larger a part gets, the more important it is that wall thickness consistency is maintained. Uneven sections of wall thickness can lead to increased defects such as sink and warp, it extends cycle times and quickly increases costs to correct the error, and there is residual stress throughout the component.

Additionally, draft, ribbing, and gate placement all become more critical in large part injection molding, especially for housings. Flow length and packing pressure losses rise with size, so careful consideration on those three aspects in design is important.

Material Selection for Large Part Injection Molding

No matter how big or small a component is, material selection is more tied toward part application, its intended environment, and manufacturing than it is to the size of the component. With our focus on housings and enclosures geared toward heavy-duty applications, this begins to narrow down the materials that make the most sense.

ABS, PC, a blend of PC and ABS, PP, HDPE, and PVC all serve is strong options for heavy-duty enclosures and housings because of their stiffness, impact resistance, chemical exposure, UV stability, and flammability needs.

By acknowledging where the enclosure or housing will perform serve will lead design and engineering teams down the correct path in material selection.

Tooling Practices

Tooling is one of the most critical aspects in large part injection molding – and one of the costliest. Large part molds require stiff tooling, vigorous cooling, and precise gating to manage shrink and warp. Cycle times are dominated by cooling of products; therefore, mold design and thermal control place a large impact on costs.

It’s common in large part molding projects that high-tonnage presses are required, but tonnage alone isn’t enough to have a successful program. Large parts are also dependent on bigger shot sizes, platen sizes, and tie-bar spacing. Connect with your manufacturer on how they handle venting, ejection, maintenance, and any trimming or assembly after molding.

Common Challenges

There’s a reason why large part injection molding isn’t often called upon, it’s because of the string of challenges that can come with it. Improper wall thickness is often the cause of product failures because warp, sink, and poor dimensional stability appear once cooling has finalized.

Compared to traditional injection molding, large part programs are also a costly venture not just including the tooling costs associated with it. The per-part cost ratio eventually dips as it does for standard injection molding programs, but it takes longer with larger parts.

Contact Port Erie Plastics for Large Part Injection Molding Services

Port Erie Plastics is a premier plastic processing manufacturing company equipped with numerous production capabilities, including injection molding. That’s how Port Erie got its start, back in 1953 when we first opened with just a single injection molding machine. Now, over 70 years later, we have 90 different machines on location to handle the most demanding injection molding services.

Injection molding of large parts is achievable at Port Erie with maximum clamping forces of 1,650 tons, shot sizes up to 470 ounces, and parts weighing as much as 24 pounds. Injection molding commonly creates small parts, but at Port Erie, we can handle it all. All components manufactured by us undergo thorough testing protocols to ensure part validation and the components can function as designed.

Our customers know that our testing and part validation services are an extension of our overall quality management systems, aimed at keeping us proficient. We’ve been continuously ISO 9001 certified for decades and maintain our commitment to quality by constantly creating new avenues to ensure our customers’ components are defect free and can function in the field of service.

Contact our team today for more information regarding large part injection molding services and how Port Erie Plastics can make a difference in your next project.

How to Select Injection Molding Materials Based on Product Application

Two of the most vital aspects of injection molding are design of the mold and the product itself, and material selection. These two factors go hand in hand with one another, and selecting the proper injection molding materials is largely dependent on your product’s intended application. 

Port Erie Plastics’ engineering team aids in material selection by viewing all of the specs of your product and communicating with your team to identify the best materials that will allow your product to function. 

Learn more about how to select injection molding materials based on your product’s application with our guide filled with considerations and best practices. 

Define Product Application Requirements 

Injection molded products can serve in numerous environments, if the right materials are used to create the products. This is perhaps the most important part of the material selection process as every consideration about the product’s application, including the environment it will serve, must be noted. 

Mechanical considerations such as a static, dynamic, or impact loads, product stiffness and flexibility, acceptable wear and friction amounts, and expected fatigue life factor into material selection. Following mechanical considerations, thermal aspects have to be discussed. This can include the standard, continuous service temperature, any peak or lows, thermal cycling, and in some cases, flame rating. 

It’s natural to go from thermal considerations directly into chemical exposure and environmental impact. Is your product going to be exposed to oils, coolants, solvents, UV rays, moisture, and/or sterilant? Does your product need to serve both indoor and outdoor, or just one? These questions all need to be considered and answered when selecting injection molding materials.

Certain industries such as the food processing industry or specific regions of the world like the United Kingdom require stringent compliance and regulatory measures on products for biocompatibility and food-safe materials, or an RoHS compliance in electronic components. 

And then a final consideration to make is from a visual standpoint. How does the product need to look? Will there be any secondary operations necessary and can the material withstand those operations? 

When all of these questions and considerations have been made, it provides the roadmap to acceptable materials to use in your product.  

Injection Molding Materials Based on Performance and Costs 

There are over 85,000 plastic materials readily available, but that doesn’t mean they all work as injection molding materials. The most common type of polymer used are thermoplastics, a class of polymer that can be liquified at high temperatures and then cooled into a specific shape. Consider these three groups when thinking about injection molding materials. 

• If your team needs low-cost materials that also have easy processing capabilities, materials such as polypropylene, polyethylene, polystyrene, and acrylonitrile butadiene styrene. These materials are commonly found in many consumer goods, packaging, and simple housings. 

• If materials need to have better heat, chemical, and mechanical properties, and your team’s budget has a little more room for spending, polycarbonate, nylon, POM, PBT, or PET polymers could be a solution. These materials are all frequently seen in the automotive, electrical, and industrial industries. 

• If your team needs the highest performance injection molding materials where cost isn’t a factor, PPS, PSU, PES, and PEEK should be researched for your program. It’s common to see these materials used to create parts for the medical and aerospace industries as they can withstand consistent high temperatures and aggressive chemicals. 

Contact Port Erie Plastics for More Information on Injection Molding Materials and Making the Best Choice 

Port Erie Plastics are experts in plastic processing manufacturing, operating out of our Harborcreek, Pennsylvania, facility. We perform various kinds of plastic manufacturing including injection molding, plastic extrusion, and structural foam molding.

As a turnkey injection molding partner, our engineering team works tirelessly to aid our customers in selecting the right injection molding materials to ensure manufacturability for their products and that they can survive in their intended application. We work with your team to understand your needs and your product’s application to narrow down the material options and select the right material. 

Contact us today to learn more about the material selection process with Port Erie Plastics and let’s take your product from blueprint to serving in the real world.

How Plastic Manufacturers Manage the Injection Molding Supply Chain and How it Benefits Customers

The demand for products and having them readily available is always on the mind of OEMs, supplier programs, and contract manufacturers across the country and around the world. Managing the supply chain regardless of the industry or product is a delicate act that truly acts like a team sport. When one hand in the supply chain has an issue, it impacts the entire chain. 

The injection molding supply chain is no different than any other supply chain and management for millions upon millions of components requires careful coordination, abundant communication, and flexibility in strategy. 

Port Erie Plastics walks through key points in the role companies like us play in the injection molding supply chain and how it’s all aimed at benefiting not only our customers, but their customers as well. 

Steps Port Erie Plastics Take in Injection Molding Supply Chain Management 

Discussing the injection molding supply chain isn’t a new topic for us as our senior leadership all the way through to our entry-level operators know how vital the supply chain is to our customers and beyond. 

We have a detailed approach in supply chain management, and it starts with assessing risk management. Port Erie Plastics works with numerous suppliers of raw materials and for every single order, we perform analysis on factors such as geopolitical tensions, natural disasters, pandemics, and even supplier bankruptcy or financial issues. When these factors have all been considered, in the event that one of them becomes a legitimate threat of disrupting our supply chain, we have built-in contingency plans in place that we enact to minimize delays.

Maintaining multiple relationships with different suppliers is in the best interests of Port Erie Plastics and our customers. If we were to only rely on a single supplier, any disruption would cause harm to our customers, and we are constantly in communication with our suppliers getting real-time updates on material availability and logistics. 

Perhaps not commonly thought of as a way to handle the supply chain, but our list of capabilities is one of our greatest strengths in managing the supply chain. We serve as a full turnkey injection molding company that includes mold design and manufacturing, transfer tooling, and numerous machining operations to keep every aspect of the injection molding project in-house and reduce outside vendors, effectively shrinking the supply chain in a positive manner. 

Customer Benefits 

Managing the supply chain properly directly impacts the customer at the end of the day, so it’s critical for companies like Port Erie Plastics to do it well. When supply chains are strong from top to bottom, customers notice positive impacts in a few key areas. 

Cost effectiveness and overall efficiency are two of the most important items to note when an injection molding supply chain is well managed. This happens in a few ways, but primarily through partnerships with turnkey injection molding companies that can handle every facet of the production process, starting with design and tooling through secondary operations and logistics. When one manufacturer oversees all these aspects of manufacturing, the supply chain is simplified into fewer users, which is another benefit. 

When manufacturers have a detailed approach to handling the injection molding supply chain, customers can expect products to have a faster time-to-market speed as a result of turnkey operations and fast scheduling throughout the production process. Additionally, delays in communications or outright missed comms windows are eliminated in an efficient supply chain.  

Issues With Your Current Injection Molding Supply Chain? Contact Port Erie Plastics Today 

Port Erie Plastics has been in operation since 1953 when we opened with a single injection molding machine. Over the last 73 years and counting, we’ve evolved into a full service plastic processing company specialized in not just injection molding, but structural foam molding, and plastic extrusion along with numerous secondary operations support all of these manufacturing methods.

Managing the supply chain for injection molding projects is something our team takes seriously. We know the difference it makes in receiving parts on time at the volume amounts and the quality that’s expected. Our numerous capabilities at handling the injection molding supply chain are built with our customers and subsequently their customers in mind. 

Contact Port Erie Plastics today for more information on our supply chain management techniques and discover how we can find a solution for you.

The Benefits of Partnering with an In-House Mold Making Company

One of the most important aspects of any plastic manufacturing operation is tooling. Whether it’s creating a whole new die for a project or transferring your tooling operation from one manufacturer to another, if your tooling operation isn’t 100 percent accurate, that can create a long list of potential problems with your product. 

Those problems are heavily mitigated when creating a partnership with an in-house mold making company. From a more streamlined production process starting at the very beginning to keep costs in check throughout the program’s lifecycle, these partnerships have a mutual benefit for customers and manufacturers a like. 

Port Erie Plastics details the benefits of partnering with an in-house mold making company and why these partnerships matter. 

Central Benefits 

There are certainly more than five benefits of partnering with an in-house mold making company, but these five advantages are perhaps the most foundational and fundamental as they impact every facet of manufacturing, relationship management, quality, and more. 

There is no way of hiding that tooling costs and mold making are the most expensive items in a production process. But when that is handled in-house by the manufacturer who’s contracted to produce your component, there are often measures built to keep costs in check. Molds built in the United States are backed by more stringent quality control measures compared to, while cheaper, lesser molds from an overseas supplier. When quality is increased, it keeps long-term costs in check through reduced downtime, lowered product reject rates, minimal maintenance, and fewer production stops. 

In the same breath about quality, through engineering capabilities and overall better material usage, the in-house team catches any design or manufacturability concerns earlier and more often than not, before the steel is cut.

If your team creates a partnership with an in-house mold making company, you’ll also notice faster turnaround times on the molds. This includes the major stops in the process including design work, tooling, engineering, and quality review. By proxy, there is more streamlined communication and an early dialogue between customers and manufacturers. Both teams can create rooted relationships before any plastic has hit the facility floor and a better, unanimous understanding of what the final result should be. 

Lastly, there is inherently more flexibility in these partnerships. In-house teams can operate on the fly as needed and customers who have changes in design or prototypes, even process adjustments, there is more grace under pressure. 

Why Partnerships with In-House Mold Making Companies Matters 

This is arguably the biggest question for prospective customers such as an OEM of a given industry. For OEMs and other customers, two of the largest weighing factors prior to any contractual manufacturing are cost and risk. Even though multiple manufacturers might make components for an OEM, it’s their name on the product at the end of the day and that carries a large responsibility. 

Partnerships like this matter because the team that’s set to manufacture your products, if they are responsible for the creation of the foundational aspect – the mold – there is a significant chance the mold is less likely to fail because of fewer responsibility and communication gaps. 

Molds can vary widely in design, especially depending upon what type of manufacturing the mold is for. Whether it’s a simple mold with minimal complexity, or a challenging mold that demands the most out of a team, a higher success rate occurs in a program through a partnership like this. 

When These Partnerships Help Most 

There isn’t a scenario where a partnership with an in-house mold making company is not going to be a helpful choice. But when it’s most helpful matters significantly. Teams that rely on these partnerships usually feature multiple revisions during the process that require easy communication. This can also include design for manufacturability support. Secondly, teams that only want to work with one partner for a product program lifecycle will often go this route to keep every aspect of the program in a single manufacturer’s hands.

Contact Port Erie Plastics and Partner with an In-House Mold Making Company Today 

Port Erie Plastics has been operating as a plastics manufacturing company since 1953. Located in Harborcreek, Pennsylvania, our team handles multiple forms of plastic production services like extrusion, structural foam molding, and the one that started it all for us, injection molding. 

Part of our manufacturing capabilities include our in-house mold making along with mold design and transfer tooling operations. Our team can create single and multi-cavity molds, stack molds, and hot runners – all customized to fit your project. Equipped with the latest technology, our engineers can perform mold flow analysis to ensure proper injection pressure, identify potential air traps, and more. 

Whether it’s transferring your existing tooling and developing a brand-new die, Port Erie Plastics is the team for you. Contact us today.

What Different Types of Injection Molds Do for Projects

Injection molding is one of the most versatile plastic manufacturing methods in the world. With cost-effectiveness for high-volume production programs, a wide range of manufacturable materials, and numerous value-added operations to further enhance a product, it’s easy to see why injection molding is so widely used. 

The most important aspect of this manufacturing method is the molds themselves and for every production run, there’s going to be a different type of injection mold. Port Erie Plastics highlights how different types of injection molds work in projects and how your team can use this guide to identify what mold might be best for you. 

Cores 

Different types of injection molds are comprised of many parts that come together to form the final product that’s used during injection molding. The first place to start is with the core itself. 

Port Erie Plastics creates stack molds which feature multiple cavities and sets are stacked vertically in order to share a common hot manifold. Stack molds are more accurate in terms of shots per cycle, and it doesn’t require an increase in clamp tonnage. Customers that require a stack mold often are contracted in a high-volume program for items such as enclosures, lids, and containers. 

But there are other forms of cores as well. Another common form is a two-plate and three-plate mold. In a two-plate mold, there is just one parting line as the cavity and core halves separate to eject the part. These types of injection molds are commonly used for programs that have simple designs and prioritize cost-effectiveness above everything else. 

In a three-plate mold, instead of one parting line like a two-plate mold, there are two parting lines. The cavity and core have a middle plate that holds the runner and gate system. Three-plate molds are used where automatic runner separation is vital for program success.

Runners 

There are two types of runner systems used in the different types of injection molds. Hot runners, which Port Erie Plastics create, maintain a heated manifold that keeps the melted plastic within the runners. Plenty of high-volume production programs rely on hot runners as they keep cycle times low, lead to reduced scrap, and contain consistent shot filling balance of the melted plastic into the cavities. 

Opposite of hot runners are cold runners where the foundational difference is that the channel the melted plastic travels through to reach the cavities is unheated. The runners themselves are ejected along with the final injection molded component. Cold runners are often associated with heat-sensitive plastics and in low to medium production volumes. While they might be more cost-effective compared to hot runners, cold runners do lead to high material waste. 

Cavities 

The final main portion when discussing varying types of injection molds are cavities. There are two forms of cavities: single and multi. In a single cavity mold, there’s only part being created per injection. Single cavity molds support prototyping projects as well as low to medium volume amounts as they can account for design changes rather quickly. 

Multi-cavity molds feature multiple identical cavities that create anywhere from two to as high as 256 parts simultaneously. If your team is considering a multi-cavity mold, it is essential to check in with your manufacturer regarding clamping force to ensure proper shot filling into the cavity. 

Partner With Port Erie Plastics to Create the Different Types of Injection Molds Your Team Needs Today 

Port Erie Plastics is widely regarded as one of the premier plastic manufacturing companies in the country because of our wide range of capabilities. While we do perform numerous manufacturing methods, we got our start as an injection molding company and from custom projects to automated programs, we stay true to our foundation. 

Thanks to our in-house mold making, mold design, and transfer tooling operations, we are well versed in different types of injection molds. We can create single and multi-cavity molds, stack molds and hot runner molds all in our Harborcreek, Pennsylvania, facility. 

Whether you need a new mold or you are having problems with your existing tooling, Port Erie Plastics is the team for you. Contact us today to learn more about how we can create your mold and let’s take your project from concept to completion.

How to Maximize Manufacturing by Taking Advantage of Plastic Engineering Services

Customers and manufacturers alike are always looking for an edge when it comes to creating parts and components. One of the best ways for both parties to create plastic parts that can separate them from the competition is by taking advantage of plastic engineering services.

These services can help improve part design, material selection, and tooling considerations, and even enhance process efficiency, all before manufacturing begins. Learn more with Port Erie Plastics and explore how to maximize manufacturing by taking advantage of plastic engineering services.

Practical Ways to Utilize Plastic Engineering Services

When using engineering services, it’s vital to use them practically and correctly. As manufacturers, this means offering the services that are most vital for a universal plastic manufacturing service, such as design for manufacturability. As customers, practical application of engineering services means having superior knowledge of your product, its intended application, and aspects where you want to see improvements in your part before production begins.

• Incorporate engineering services early on in your project, so when design changes happen, they are more cost-effective, quicker, and won’t impact tooling.
• Utilize design for manufacturability reviews to better enhance your design by simplifying geometry, reducing secondary operations, and standardizing features.
• Request material selection assistance, as plastic engineers will have expert knowledge of materials and can pair that with your part’s intended application.
• Ensure that quality management systems are paired with engineering services such as SPC, part validation testing, and process monitoring.

Where Value Presents Itself

The big question has to be asked. Where is the value in plastic engineering services? These services are intended to boost product efficiency, performance, and service life, all while delicately balancing the ever-important cost factor for both customers and manufacturers.

One of the key ways all the goals of plastic engineering services are achieved is through material selection guidance. Whether it’s a customer’s first project or merely their first of the month, engineering teams at experienced manufacturers have seen countless examples of proper material selection with intended part application. When the right material is selected, this better ensures enhanced part performance.

Impact on Manufacturing

Plastic engineering services don’t just impact the customer and their components. Manufacturers running production on components that have undergone thorough engineering services are going to experience impacts as well, which have a trickle-down impact on customers.

• Manufacturers experience higher throughput, meaning customers get their orders faster.
• Scrap material and overall waste can drop drastically when engineering services are performed, saving on costs for both manufacturers and customers.
• Shorter lead times are also achievable with engineering services.
• With engineering services catered to design, manufacturers experience a more streamlined process in production, along with more accurate material usage and handling.
• While engineering services can increase initial upfront costs, they are intended to stave off long-term costs by identifying and reducing, or even eliminating, costly rework.

Trust Port Erie Plastics With Your Plastic Engineering Services

Port Erie Plastics is one of the longest tenured plastic manufacturing companies in the United States. We started out with a single injection molding machine, a small team, and a vision to create high-quality plastic components for OEMs across countless industries. What’s transpired since is multi-faceted plastic manufacturing serving the entire country.

Our plastic engineering operations are led by a highly skilled and knowledgeable team of engineers, where one engineer is assigned to every project that comes through our door. From material selection advice to tooling and die design considerations, and everything in between, our engineering services are aimed at enhancing all aspects of the manufacturing process.

Discover the difference in manufacturing by taking advantage of Port Erie Plastics’ engineering services, and contact us today.

A Guide to Different Plastic Manufacturing Processes: Key Benefits, Top Considerations, and Best Applications

Understanding the roles that different plastic manufacturing processes play throughout the manufacturing landscape can help OEMs and other potential customers know which production methods might be best suited for their next line of components and products.

Port Erie Plastics’ guide to different plastic manufacturing processes is a comprehensive overview of the methods themselves, key benefits of production, and top considerations to make before selecting a specific process.

Key Benefits of Different Plastic Manufacturing Processes

Port Erie Plastics has three different forms of plastic manufacturing processes we perform in our facilities: injection molding, plastic extrusion, and structural foam molding. These three services are the ones we’ll focus on here.

Benefits of Injection Molding

• Injection molding is a highly repeatable process once the mold design has been finalized and properly tooled. Molds can be used over and over again as long as they are properly maintained.
• Additionally, since the process is highly repeatable, it is also a fast production method.
• High-volume production orders are best suited for injection molding as the cost-per-part ratio drops dramatically after tooling costs.
• Since melted plastics are shot into the mold and it takes the shape of the mold, complex designs are possible through injection molding.
• Minimal waste is created through injection molding as it is an additive process rather than one that involves trimming material into a shape.

Benefits of Plastic Extrusion

• Plastic extrusion is often viewed as one of the most cost-effective plastic manufacturing processes on the market because of the use of automation in the process and the ability to create continuous shapes.
• Extrusion is the choice for many OEMs and other customers when they need parts that include cross-sections.
• Multiple materials can be used in a singular extrusion run (co-extrusion), blending materials and leading to further enhanced parts.
• Extrusion operations use highly efficient thermoplastics that can be reused over and over again, leading to material efficiency and minimal waste.
• Parts made through extrusion feature consistent high quality.

Benefits of Structural Foam Molding

• Parts created through structural foam molding traditionally boast a higher strength-to-weight ratio compared to other plastic manufacturing processes.
• In low-pressure structural foam molding, less clamping force is required during manufacturing, which can make it a more cost-effective solution.
• Structural foam molding is best suited for large part manufacturing.
• Structural foam molding can create parts with enhanced performance, specifically chemical, impact, heat, and weather resistance.
• The process creates minimal defects, such as sink and warpage.

Considerations Before Selecting a Manufacturing Process

After viewing the benefits of the different plastic manufacturing processes, these advantages are the guiding principles when selecting a production method. But let’s break it down further.

Select Injection Molding If

Your team needs fast turnaround times where the manufacturing process features fast cycle times. Parts created through injection molding are best suited for high-volume production as the cost-per-part ratio drops quickly, offsetting the tooling costs.

Select Plastic Extrusion If

Your team needs continuous shapes that feature simple or complex cross-sections that are integral to the overall structural integrity of the part.

Select Structural Foam Molding If

Your team needs parts with a higher strength-to-weight ratio and complex geometries that are going to serve in demanding environments. Additionally, if your team needs lower production costs and large part sizes, structural foam molding can align well with your end goal.

Best Applications of Different Plastic Manufacturing Processes

With benefits and considerations covered, the most direct way to showcase which manufacturing process is best for your team is by listing out real-world applications of each process.

Applications of Injection Molding

• Dashboard components in the automotive industry
• Bumpers
• Laptop enclosures
• Mobile phones
• Tubing connectors in the medical industry
• Syringes
• Caps and closures

Applications of Plastic Extrusion

• PVC pipes
• Siding
• Window frames
• Weather stripping
• Plastic films
• Gaskets

Applications of Structural Foam Molding

• Reusable pallets and containers
• Large waste bins
• Point of sale machines
• Kiosks
• Display racks
• Large panels

Contact Port Erie Plastics for All Your Plastic Manufacturing Needs

Port Erie Plastics opened its doors in 1953 with a single injection molding machine, and over the course of 70-plus years, we’ve expanded our capabilities into a multi-faceted plastic manufacturing company.

We’re able to perform different plastic manufacturing processes because of the relationships we’ve built with our customers, allowing us to adapt to their industries and invest in the knowledge and infrastructure necessary to produce the components they need, when they need them. No matter which manufacturing process we’re performing, all of our production methods are backed and vetted by our ISO 9001 certification, which demonstrates our quality management systems.

Whether it’s injection molding, plastic extrusion, structural foam molding, or one of our other capabilities, Port Erie Plastics is ready to take your project on. Contact our team today.

Inside Plastic Injection Molding Design Services and What They Entail

Injection molding services don’t start when the machines turn on. They start when engineer and design teams begin consultations with your group. The right plastic injection molding design means a smooth, streamlined manufacturing process that enables easier production and ensures the benefits of injection molding for your components.

Port Erie Plastics provides an inside look at plastic injection molding design services, including what they entail and how to maximize design services to experience a better manufacturing process.

Common Plastic Injection Molding Design Services

While not meant to be a complete list, these design services for injection molding projects provide a glimpse into what manufacturing companies and their engineering teams can do for your project.

• Design for manufacturing and manufacturability review entails design and engineering teams crafting a design alongside you, with knowledge of part application. This allows for proper material selection and key aspects such as wall thickness, bend radii, and more. If you are bringing a design to the table, engineering and design teams review your specs to ensure the part can be manufactured.
• Design services go hand in hand with material selection because design aspects have to be in place with material selection, and certain materials can withstand certain design aspects. Ultimately, both have to work together toward the part’s intended application.
• When crafting the design for your component, you also have to consider your tooling strategy. This includes making notes on whether it will be a multi-shot or single-shot cavity. Additionally, considerations on runners and gates must be made, as this will impact cycle times and part quality.
• Engineering teams can run samples such as moldflow or flow simulations that can gauge predictable shot filling, weld lines, sink marks, air traps, and warpage before cutting material used for tooling.
• Lastly, prototyping services can produce a rough version of your component, which can be used to alter the design as needed before full-scale production begins.

Why Design Services Matter

It’s one thing to have trust in your design and submit it for manufacturing and wait for your order to show up at its final destination. But utilizing design services will enhance your initial attempt. Consider these points if you’re on the fence about using design services for your injection molding project.

• Plastic injection molding design services can ultimately reduce tooling costs by eliminating needless aspects in an initial design and trimming down sections. This is reflected in the mold and subsequently in the final injected product.
• Not only can it reduce tooling costs, but it can also drastically reduce tooling changes.
• Design services identify potential part defects, and when those are addressed, there is a plan in place to respond and eliminate defects.
• While the main focus is to ensure part manufacturability, design services can positively impact lead times, pricing, and volumes.

Contact Port Erie Plastics for Plastic Injection Molding Design Services Today

Port Erie Plastics specializes in multiple forms of plastic manufacturing and the design and engineering services necessary to make these projects possible. We started our company with a single injection molding machine in 1953 and have expanded to other forms of manufacturing, including structural foam molding, extrusion, and more.

Our plastic injection molding design services and engineering services are made possible by dedicated engineers trained in taking projects from concepts to tangible results.

Contact Port Erie Plastics today, and let’s get started on your project design.

How to Select Injection Molding Materials Based On Product Application

Material selection is one of the most important aspects of any manufacturing process. It defines how the product will survive in its given application and environment, and selecting the right material can be the difference between a long-lasting component and a product that’s destined to fail.

But how to determine the necessary injection molding materials? Knowing the part’s intended application allows engineering teams to help guide you in selecting the best material. Port Erie Plastics’ guide on how to select injection molding materials based on product application is a comprehensive set of examples on matching materials we use every day with common applications.

Define Product Application

When your team has a clear understanding of both your product and its intended design, material selection narrows from vast possibilities to the best options. There are a few parameters to determine and define, however, when discussing your product’s application, both internally and with your manufacturer’s design and engineering team.

• Weigh how much mechanical strength your part will need to avoid defects during application. If you’re having components manufactured that will be part of a bigger assembly, determine if the component can rely on the mechanical strength of the larger piece.
• Ask what forms of resistance are needed for the component to succeed in its environment. This can include resistance to impact, heat, chemicals, UV, and moisture.
• Does the part need to look a specific way? If so, consider whether value-added operations will be needed to alter the material’s appearance once manufacturing has concluded.

Commonly Used Injection Molding Materials

Many injection molded products feature similar or overlapping applications where the polymers used contain shared properties and characteristics that allow the components to thrive in given environments. Below are some of the most commonly used materials with product benefits and application examples.

Polypropylene and Polyethylene

Polypropylene (PP) and polyethylene (PE) are two of the most commonly used injection molding materials, largely because of the many benefits naturally found in both. They are both cost-effective materials and feature good chemical resistance along with impact resistance. Additionally, PP features positive fatigue resistance.

Because both materials are so commonly used, they can be found in numerous applications from general consumer parts to interior automotive parts, and food industry items such as utensil handles.

Acrylonitrile Butadiene Styrene and Polycarbonate

Acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) are right behind PP and PE for commonly used materials in injection molding. These two materials can be used for several applications, including enclosures, consumer electronics pieces, and cosmetic housings. ABS is selected because it balances structural integrity, toughness, and aesthetic properties. It’s also a lightweight material and a good source of electrical conductivity. PC contains high heat resistance, creep resistance, and good toughness, making it ideal for electrical applications.

Nylon and PP

For automotive applications, nylon and PP are good selections for injection molding materials. Both polymers feature strong resistance to elements found in heat, oils, fuels, and the functional aspects of automotive applications.

Contact Port Erie Plastics for Expert Solutions in Injection Molding Materials

While Port Erie Plastics performs multiple variations of plastic manufacturing in our Harborcreek, Pennsylvania, facility, we specialize in injection molding. We started with a single injection molder in 1953 and never lost sight of the manufacturing process that made us who we are today.

Over time, injection molding material options have expanded, all with their own benefits and applications. Our dedicated engineering team continues to invest in education on materials as well as understanding the best applications of those materials, so customers can be confident in our expertise.

Get the most out of your injection molding materials and contact Port Erie Plastics today.