AIM Processing Small Plastic Parts Blog

Plastic overmolding is a unique injection molding process that we use to mold custom components over top of other molded parts. A specialized form of multi-shot injection molding, overmolding allows us to mold one plastic part design onto another – typically a stronger, more rigid plastic base, or internal metal components combined with overmolded plastics.

The injection molding industry continues to evolve through the adoption of newly engineered plastic materials and emerging production technologies.

Draft angle is a critical concept in plastic injection molding. It directly affects both the quality and manufacturability of plastic parts, so it’s crucial to get it right from the start to avoid production issues down the line. Worse, it can be a detail that can render your injection mold useless.

Put simply, draft angle refers to the taper or angle that is designed into the vertical walls of a plastic part, relative to the vertical axis of the mold. Properly tapered walls ensure that the finished part can more easily eject from the mold after the forming process is complete. Essentially, an optimal draft angle is necessary because it prevents the part from getting stuck in the mold cavity due to the friction between the plastic material and the mold surfaces on the texture side and the suction between the plastic material and the mold surfaces on the interior side.

Insert molding is integral for many plastic injection molded products that require threaded connections, high-strength fasteners, or other metal components integrated straight into the plastic. While these complex part features could potentially be produced through injection molding alone, insert molding allows us to combine the increased strength and durability of metal with the flexibility of plastic molding.

Below, we take a look at some of the most common insert molded products, along with some of the advantages that metal inserts bring to the table.

Your custom injection molded products are only as good as the designs on which they are based. The injection molding process is delicate and complex, requiring precision designs and specifications to ensure a quality end product. Everything from the size and shape of the components to the strength requirements must be factored into the design in order to optimize the production process.

Moreover, there are a multitude of unique thermoplastic materials to choose from. In order to optimize your products for both cost and functional performance, we must consider (and sometimes test) numerous different materials in the design phase.

When it comes to designing custom injection molded products, choosing the right material is crucial. Optimum material choice ensures that the final products exhibit the quality and durability that you expect, as well as all of the desired performance aspects. Product costs are also often a major consideration in material choice.

Of course, there are a multitude of different injection molded plastics to choose from, each offering unique strengths and performance advantages. However, choosing the ideal molded plastic material isn’t always an obvious process. There are many complex material properties and production issues to consider.

In today's highly competitive and diverse market of molded plastics, ensuring success goes beyond the basic functionality and aesthetics of the products. While those aspects remain crucial, successful projects are backed up by a further understanding of their respective markets, their end users, and the unique needs they bring to the table.

This is where user-centered design (UCD) plays a pivotal role in plastic injection molding, considering the end-user experience first and foremost throughout product development. When combined with the precision and efficiency of the injection molding process, UCD can result in custom products that meet or exceed user expectations while also being as cost-effective and sustainable as possible.

For at least the past decade, plastics have often been considered negatively in discussions concerning sustainability and eco-friendliness. But most of this is tied to single-use plastics and how they are handled after usage. Looking further upstream to plastic manufacturing, the reality may be more eco-friendly than one would think. The modern injection molding sector has become more and more concerned with sustainability and environmental friendliness. From the plastic materials that make up the products to the production equipment that molds them, along with all of the complex logistics behind shipping and supply chain management – today’s industry demands better sustainability at every turn.

Plastic injection molding services are increasingly crucial within today’s medical and tech sectors. From state-of-the-art medical devices and specialized healthcare equipment to complex electronics components and everyday gadgets, molded plastic products can be found in virtually every facet of modern day life.

Of course, medicine, healthcare, electronics manufacturing, and the various tech industries are some of the fastest growing markets in Colorado and across the nation. More and more vendors in these niches are demanding the highest quality American injection molding companies to manufacture their products lean, reliably, and as sustainably as possible – all while simplifying their supply chains. Enter AIM Processing, one of the greater Colorado region’s leading injection molding service providers.

Nylon is a highly versatile thermoplastic material that is used in many specific injection molding applications today. An extremely durable and chemically-resistant plastic, nylon is commonly used in automotive electronic connectors, protective casings, enclosures, metal replacement parts, and high-wear mechanical components.