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injection molding dieAt Abtec Inc., we’re proud to offer custom mold making services, helping clients bring their product visions to life. Versatile and reliable, plastic injection molding is used to create a huge range of everyday products. One of the most popular methods for mass producing plastic parts, this technique continues to rise in popularity across diverse industries and applications. Some of plastic injection molding advantages include the following:

  • High Efficiency and Quick Turnaround Times

    Plastic injection molding is one of the most efficient methods for producing machined plastic parts. Since periods between cycles can be as short as 15 seconds, more parts can be made — meaning thousands of precision parts can be produced per hour, depending on the specific mold. This high production output rate helps companies boost revenue and profit margins.

  • High Accuracy for Complex Part Designs

    Custom plastic injection molding allows for great design flexibility. Nearly any type of plastic part can be produced using this manufacturing process, and the molds allow the finished product to be extremely precise, typically within 0.005 inch.

    Having a full understanding of customers’ needs is imperative for ensuring proper product form and function. With years of industry experience and a dedication to close client collaboration, our team is able to determine the ideal design and material for customers’ projects, and can begin work quickly on prototypes.

  • Wide Range of Material Options

    Our team’s deep expertise is invaluable when deciding on the ideal material for a part. Material selection is a critical step in the manufacturing process, and must be based on the intended strength of the end product. Other key factors to keep in mind include appearance characteristics, such as color and finish, and any applicable regulatory requirements. Dozens of material options are available to meet specific application needs.

  • Automation Capabilities

    More and more aspects of the injection molding process can now be automated. Robotics automation allows repetitive actions to be carried out quickly and efficiently, without the risk of variation. During the injection mold process, automation can be used for various tasks, such as removing parts from plastic injection molds or positioning inserts or metal components into the molding machine. Robotics can also be used for secondary services, such as assembly, packaging, drilling, and sorting. Automation offers a range of unique benefits, including highly consistent, improved part quality, as well as reduced costs, less waste, and enhanced machine utilization.

  • Cost Savings

    Plastic injection molding is cost-efficient for a number of reasons. First, injection molding machines often run with a self-gating tool to streamline operations and keep production going smoothly passing the cost savings off to the customer.

  • Endless Possibilities

    With a huge range of design, material, and color options, nearly any kind of part can be created with the custom injection molding process. Color and material type are easy to change in plastic injection molding machines, and one mold can produce many variations of the same product. Abtec also provides a number of secondary services, allowing for further customization. Popular services include milling, drilling, CNC machining, hot stamping, ultrasonic welding, heat staking and painting.

Why Choose Abtec for Custom Injection Molding Services?

plastic granules

Abtec will be there with you year after year; as many of our customers have been with us for 30 plus years.

Along with the many injection molding advantages we provide, we’re with you every step of the way. We know our customer needs, their scheduling and buying habits; we are prepared and quickly respond to our customers needs.  You get your product when you want it … on-time with quality you can trust.

Abtec is a qualified and certified ITAR/DOD and JCP injection molding company providing sub-tier government suppliers confidence in your services.  In addition, Abtec is ISO 9001:2015 certified with a QMS that provides customer confidence in the quality and services we provide.

Abtec can comply with your product specification and not have your sacrifice or compromise as we assist with design for part manufacturability.  We work with you and understand your expectations and challenges.

Abtec utilizes the best molding practices and communicate with you to provide satisfying results. Continuous interaction with our customers, Abtec will create with your company a solid business relationship foundation that will benefit and project development process.

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No matter what kind of part is needed, the experts at Abtec know how to turn your idea into a high-quality finished product. We offer both high- and low-volume production capabilities for custom plastic injection molded parts, and guarantee on-time delivery for every order.

To learn more about our injection molding advantages and discuss how we can help with your unique application needs, reach out to the team today. We’re on hand to answer any questions you may have about injection molding products and processes.

injection molding advantages

A Guide to Our Engineering Resins

Engineering resins are one of two types of plastics commonly used in the injection molding process. Commodity resins (the other common type) are inexpensive and typically used in consumer products like toys, packaging, and food containers. Engineering resins are ideal for use in industrial applications because they are strong and highly resistant to temperature, corrosion, and wear. Engineering resins also have special thermal and mechanical properties that make them useful in replacing wood and metal to save on costs and/or weight.

 

Abtec, Inc. offers a broad range of different engineering plastic resins that can be used in industrial projects.

Engineering Plastics Available from Abtec

The engineering plastics we offer include:

  • Acetal Copolymer Polyoxymethylene (POM), also known as Celcon or AmcelAcetal, also known as polyoxymethylene (POM), is a semi-crystalline thermoplastic often used to create precise parts that require high resistances to environmental factors such as heat and abrasion, good dimensional stability, and low friction. Acetal also features a high enough tensile strength that it is useful for replacing metal in some applications. POM is used for applications such as plastic zippers, small gears, medical devices, and consumer electronics.

 

  • Polybutylene terephthalate (PBT) is a semi-crystalline polymer with high molecular weight. It has high heat and chemical resistances and favorable electrical properties. PBT features higher flexural, dielectric, and tensile strengths than most other thermoplastics. Glass-filled PBT exhibits 2–3 times as much strength in these same areas.

 

  • Polyethylene terephthalate (PET) is hard, stiff, strong, and dimensionally stable. It features a good resistance to chemicals other than alkalis and exists as both an amorphous and a semi-crystalline thermoplastic material. Semi-crystalline PET features good strength, ductility, and hardness while amorphous PET offers better ductility but less hardness and stiffness.

 

  • Polycarbonate (PC) is a naturally transparent, amorphous thermoplastic. It is available commercially in a wide range of colors, and its polymers are useful in producing materials that require impact resistance and/or transparency. Common applications include plastic lenses in eyewear, automotive components, and exterior light fixtures.

 

  • Polyether ether ketone (PEEK) is a semi-crystalline polymer with good thermal stability due to its high melting point of 300° C. It possesses a high chemical resistance and is created with fiberglass or carbon reinforcements to enhance mechanical and thermal properties. PEEK is non-flammable and has good dielectric properties.

 

  • Polyether imide (PEI) is an amorphous polymer exhibiting high temperature resistance, creep resistance, and rigidity. Since it is non-flammable, resistant to radiation, and easily processed, PEI is approved by the FDA for use in medical and food contact applications.

 

  • Polyethersulfone (PES) and Polysulfone (PSU) exhibit high thermal, oxidative, and hydrolytic stability. These thermoplastics are amorphous, transparent, and can be molded, extruded, or thermoformed into a variety of different shapes. PES and PSU are typically used for internal components in coffee machines, battery containers, and printer cartridges.

 

  • Polyphenylene ether (PPE) has low moisture absorption, giving it good electrical insulating properties over a wide range of temperature and humidity conditions. It also has good resistance to water and most salt solutions. Its applications include food processing, automotive parts, and household appliances.

 

  • Polyamide (Nylon) is a synthetic thermoplastic that can be heated to its melting point, cooled, and reheated again with minimal degradation. Glass-filled Nylon has higher tensile strength but is more brittle than traditional Nylon. Nylon’s wide variety of uses include clothing, toys, and furniture points of impact.

 

  • Polyphenylene sulfide (PPS) is a crystalline material that is highly resistant to temperature, chemicals, and corrosion. It also has high flame retardance, making it common for use in high-temperature electrical applications.

 

  • Thermoplastic elastomer (TPE) is a flexible material that can typically be pulled to at least twice its original length at room temperature. It offers slip resistance, shock absorption, and ergonomic comfort. It can be easily molded onto hard thermoplastic materials, making it ideal for use as a soft touch grip on a product. Other typical applications include sealing rings and bottle cap liners.

 

  • Thermoplastic polyurethane (TPE/TPU) offers the elasticity of rubber and the toughness and durability of metal. It ranges from being very soft and flexible to very rigid. TPU has excellent resistance to abrasion, good performance in low temperatures, and high transparency. Typical uses include automotive interior and exterior parts, hydraulic seals, and medical devices.

Abtec has more than 100 years of experience in injection molding. We are ISO-certified and ITAR/DOD-registered.

 

If you need custom injection molding involving any engineering resins and/or any commodity resins we work with, please contact us.

plastic granules

 

There are instances in manufacturing where metals cannot meet the weight and deflection demands specified by the application. When this is the case, thermoplastics often provide a solution. Thermoplastics are among a group of materials that melt when heated. They are common in manufacturing because heating makes them viscous, allowing for the formation of specific shapes which the material retains after cooling.

Injection molding is the most common method for thermoplastic processing. There are a broad range of resin materials used in injection molding, including thousands of materials categorized as thermoplastics. At Abtec, Inc., we specialize in injection molding and in the identification of materials

Consequently, making the right choice to fit a specific application can be a daunting task. Abtec helps our clients choose the right thermoplastic materials for their design and application based on our thorough industry knowledge and significant experience with the injection molding process. This page will provide readers with a better understanding of the various thermoplastic types and the process of injection molding as a beginning point.

 

Polyolefin High Density Polyethylene (HDPE)

What to Know About Thermoplastics

There are thousands of resin compounds included under the definition of thermoplastics, making it difficult to distinguish which ones might best serve various applications. However, classifying these resins into nine categories helps simplify things considerably. The nine categories include:

  • Acrylonitrile butadiene styrenes (ABS). ABS is the most recognizable material by most consumers. Even at low temperatures ABS plastics are rigid and tough. They offer dimensional stability, abrasion resistance, chemical resistance, heat resistance, and provide balanced tensile strength.

 

  • Acetal Copolymer Polyoxymethylenes. This thermoplastic is easier and faster to process than traditional homopolymer resins due to its lower melting point. These thermoplastics are creep-resistant, remain stable when used in high temperature applications over a long period of time, and have good moisture resistance. Additional qualities include excellent lubricity, high tensile strength, and fatigue resistance.

 

  • Acetal Homopolymer Polyoxymethylenes. Distinguishing features of these thermoplastics include toughness under repeated, moderate impact along with high tensile strength, stiffness, resilience and the highest fatigue endurance of all unfilled thermoplastics. They also feature low moisture absorption properties, along with high abrasion resistance and creep-resistance.

 

  • Acrylics. This type of thermoplastic is a common substitute for glass in a variety of applications. These thermoplastics transmit and control light and possess outstanding weatherability and scratch resistance. They are also stable against discoloration and possess low haze and scratch resistance, making them ideal for optical applications.

 

  • Polycarbonates. These plastics present exceptional toughness over a wide range of temperatures. This category of thermoplastics includes a broad range of grades ranging from general-purpose and extrusion molding to special grades with flame retardant properties or contamination resistance for food processing and medical applications. Dimensional stability, heat resistance, toughness and transparency are distinguishing features of polycarbonates.

 

  • Polyethylenes. Low water absorption, dimensional stability, hardness and stiffness are some of the main characteristics of this type of plastic. They are available in both amorphous (transparent) and semi-crystalline (opaque) forms. Gas barrier and chemical resistance properties (except for alkalis) make these plastics valuable for a broad range of manufacturing applications.

 

  • Polypropylenes. These plastics feature a lower density with good thermal, chemical, and electrical use properties. Due to their limited heat resistance, they require heat-stabilization to perform well at high temperatures. They have less toughness than high-density polyethylene and are less brittle than low-density polyethylene, but they have a high resistance to fatigue, making them an ideal solution for plastic hinges.

 

  • Polystyrenes. These low-cost amorphous thermoplastics have a lower heat resistance than the other types and require a continuous service temperature that is below 200º F to maintain their integrity. However, their characteristics include excellent colorability, processing ease, hardness, and clarity as well as good electrical properties at room temperature and under normal levels of humidity.

 

  • Nylons. A broad range of grades are common within this classification of thermoplastics and each has its own valued properties. In general, Nylon features good fuel, oil, and chemical resistance properties along with excellent fatigue resistance, good toughness, and a low friction coefficient.

 

Please note: The above is not a complete list of all the materials which Abtec can utilize for your project. Click here for a complete list of our plastic injection molding materials and thermoplastics!

 

An understanding of the general properties of each of these types of plastics can help narrow down the selection process for specific applications. Users must keep in mind that various grades highlight different properties within each classification.

 

Acetal Copolymer Polyoxymethylene (POM), also known as Celcon or Amcel

The Advantages and Disadvantages of Thermoplastics

The various types of thermoplastics used for injection molding include a broad range of advantages and disadvantages for specific applications. However, there are some general advantages and disadvantages common to thermoplastics. The advantages include:

  • Energy efficient processing
  • Broad range of beneficial properties
  • High volume manufacturing with excellent precision at lower cost
  • Various types can replace metals with a considerable weight-saving advantages
  • Higher fatigue resistance than most metals
  • Greater deflection toleration than most metals without deforming

These advantages make thermoplastics ideal for an expansive range of designs and applications. However, the following are disadvantages among thermoplastics, which may impact material selection:

  • Thermoplastics degrade more easily in direct sunlight or under UV exposure
  • Not all thermoplastics resist hydrocarbons, organic solvents, and polar solvents
  • Some types experience creep under long-term loading
  • Can fracture rather than deform under high stress

It should be noted that these disadvantages are not common for all thermoplastics, which makes proper selection of the right material a critical consideration for applications which may experience any of the above conditions.

Applications of the Common Types of Thermoplastics

Thermoplastics are extremely important in manufacturing, covering a wide range of applications throughout almost every possible industry. Consequently, it is easier to list some of the various applications of each type of thermoplastic rather than attempt to identify their use by specific industry. Some of the common uses of each type include:

  • ABS: LEGO bricks, safety hats, whitewater canoes, musical instruments
  • Acrylic: Lucite, Perspex, Plexiglass
  • Polyester: Yarn, rope, conveyor belts, clothing, furniture, blankets, mouse pads
  • Polypropylene: Lab equipment, carpets, textiles, packing, labeling
  • Polystyrene: Foam cups, smoke alarm housings, models, disposable cutlery, CD/DVD cases
  • Cellulose Acetate: Cigarette filters, playing cards, eyeglass frames, adhesives, photography
  • Nylon: Carpet, rope, strings for musical instruments, fishing line, fabric

What is the Difference Between Thermoplastics and Thermoset Plastics?

There are some close similarities between thermoplastics and thermoset plastics which make it necessary to distinguish between them. The main difference between the two relates to how they react to heat. You can melt and reform thermoplastic numerous times, but thermoset plastics cure after heating and can be formed only once.

 

Polyolefin Polyethylene (PE)

Abtec Provides Custom Injection Molded Thermoplastics

Custom injection molding of thermoplastics is a primary specialty of Abtec. Though the process is simple, significant expertise is required to achieve tight tolerances and high repeatability. Our expertise in injection molding comes from a thorough understanding of engineering concepts surrounding thermoplastics and how each type should or should not be used.

In addition to the injection molding process, we also provide custom mold design and mold making to meet the precise component specifications, timelines, and budget costs of each client. Our value-added services allow one-stop, in-house solutions that include:

  • Sonic welding and heat staking
  • Final assembly and kitting
  • Packaging with blister packs, header cards, or boxing
  • Protection from contaminants in our Class 10 ISO 4 clean work cell

The expertise and special care taken by Abtec on every project provides our clients with the assurance of quality and top-rated service for all their injection molding and thermoplastic needs.

The injection molding process of thermoplastics is critical in a broad range of industrial applications. A thorough knowledge of the injection molding process and of thermoplastic materials allows us to produce durable components with a variety of properties and characteristics. Ultimately, injection molding supports high-volume, precision production at a lower cost.

Abtec, Inc. has the expertise necessary to provide advanced thermoplastic injection molding along with a variety of value-added solutions to meet the needs of our clients.

Contact us to learn more about the solutions we can provide for your organization.

 

Abtec, Inc. offers injection molding services for custom molds based on your design. We have a broad catalog of materials and thermoplastics, plus years of expertise to help get the job done right!

Read our infographic below for some of the major advantages of custom injection molding, then contact us for more info or to request a quote!

 

infographic for advantages of custom injection molding plastic