F&Q TECH's High Quality Injection Molding

Stage 1: Plasticization


1. Overview



When the factory starts injection molding production, it will purchase the corresponding raw materials according to the product requirements. Commonly used raw materials are ABS\PC\PP, etc. After the raw materials are ready, we start our first step: plasticization. The main purpose of the plasticization process is to heat and melt the raw materials (plastic particles) into a flowable liquid form.





2. Detailed process



Feeding: Feed the plastic particles into the barrel of the injection molding machine through the feeding port.
Heating: A heater inside the barrel heats the plastic pellets above the melting point, usually between 150°C and 350°C, depending on the type of plastic used.
Mixing and shearing: The screw rotates in the barrel, mixing and shearing the molten plastic to ensure that the material can be uniformly and consistently transferred to the next step.






3. Key Factors



Temperature control: ensures that the plastic is fully melted but not excessively degraded.
Screw speed: affects plasticization and mixing effects.


Stage 2: Injection

1. Overview



The injection stage is the process of injecting the molten liquid into the mold.





2. Detailed process



Mold Closure: The two halves of the mold are tightly closed to form a cavity.
Injection: The screw moves forward, injecting the molten plastic into the mold cavity through the nozzle.
Pressure Holding: During the cooling and solidification of the plastic, a certain pressure is maintained to ensure complete filling and dimensional stability.




3. Key Factors



Injection speed: affects filling time and filling quality.
Holding time: affects the dimensional stability and internal stress of the product.


Stage 3: Coolding

1. Overview



The cooling phase is the process by which the plastic cools and solidifies within the mold.




2. Detailed process



Cooling time: Determine the appropriate cooling time based on product thickness and material properties.
Cooling medium: Use water or other cooling medium to exchange heat through the cooling channels in the mold.




3. Key Factors



Cooling rate: affects the crystallinity and internal stress of the product.
Mold temperature: affects the surface quality and dimensional accuracy of the product.


Stage 4: Demolding

1. Overview



The demoulding stage is the process of removing the solidified plastic product from the mold.





2. Detailed process



Mold opening: The two halves of the mold separate.
Ejection: The ejection mechanism pushes the product out of the mold.
Removal: The product is removed from the mold manually or by a robot.




3. Key Factors



Ejection force: Ensure that the product is smoothly released from the mold without excessive deformation.
Ejection position: avoids scratches or damage to the product surface.


Conclusion

The four stages of the injection molding process - plasticization, injection, cooling and demolding - are each critical and affect the quality and performance of the final product. By deeply understanding and optimizing these stages, manufacturers can improve production efficiency, reduce scrap rates, and produce high-quality plastic products.







Hopefully this article will help you better understand the four key stages of the injection molding process. If you have any questions or need further advice, please feel free to contact us.

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In April 2025, Apple CEO Tim Cook said in an interview: "The core reason why Apple insists on manufacturing in China is not cheap labor, but China's irreplaceable 'skill density'." This view not only reveals the underlying logic of Apple's supply chain, but also reflects China's global competitiveness in the field of precision manufacturing. This article will deeply analyze how China has become the preferred partner for CNC processing and mold injection services for European and American companies by relying on its technical talent reserves, supply chain efficiency and innovation ecology.



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1. The core competitiveness of China's manufacturing: the transition from "cheap" to "skill density"

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1.1 “Skill Density” in Cook’s Eyes

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Cook has repeatedly stressed that the core advantage of China's manufacturing industry lies in its large-scale and systematic talent pool. For example, the number of mold engineers in a certain province in China can "fill several football fields", while the United States "can't even gather enough engineers for a meeting." This gap stems from:
Education system support: China's vocational education system focuses on training technical workers, covering high-skilled fields such as CNC programming and mold design.
Industry chain collaboration: From raw materials (such as aluminum alloys and engineering plastics) to precision processing, China has formed a "one-hour industrial circle" to achieve rapid response and cost optimization.


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1.2 The “micrometer-level” threshold for precision manufacturing

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Apple products require mold precision up to micron level (such as the surface fit of iPhone shell), which relies on the following technological breakthroughs:
Popularization of 5-axis CNC machining: China's leading factories have widely used 5-axis linkage machine tools, which can process complex curved parts with an accuracy of ±0.01mm.
Injection molding process innovation: For example, the glass panel produced by Lens Technology for Apple Vision Pro uses high-precision hot bending technology, with a yield rate of over 99%.








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2. Four major driving forces for European and American companies to choose Chinese suppliers



2.1 The ultimate balance between cost and efficiency

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Dimensions

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Comprehensive cost

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Delivery cycle

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Technical adaptability

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Chinese Manufacturers

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Labor + equipment depreciation costs are 30%-50% lower

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Average 2-4 weeks (relying on clustered supply chain)

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Support flexible production from prototype to mass production

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European and American local suppliers

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High labor cost, suitable for small batch customization

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Prefer standardized large-volume orders

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Complex parts take 6-8 weeks



Case:
A German car brand transferred its aluminum alloy wheel CNC processing orders to China, reducing costs by 40% and shortening delivery time to 3 weeks.
A US medical company commissioned a Chinese manufacturer to produce disposable endoscope housings by injection molding, which passed ISO 13485 certification and had a defect rate of less than 0.1%.




2.2 Green Manufacturing and Compliance



Carbon neutrality goal: China's leading suppliers (such as BYD and Luxshare Precision) have pledged to achieve carbon neutrality for Apple orders by 2030, using environmentally friendly materials such as recycled aluminum and bio-based plastics.
Process optimization: Through AI-driven tool path planning, material waste in CNC processing is reduced, and the waste recovery rate exceeds 90%.








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3. The hidden advantages of China’s supply chain: Taking Apple as an example



3.1 Upgrading from “assembly” to “core technology”



Cook clarified: "The iPhone is not only 'assembled in China', its core components (such as glass cover and metal structural parts) rely on the precision processing capabilities of Chinese manufacturers." For example:
Lens Technology: Provides super-ceramic glass panels for iPhone, with 4 times higher drop resistance, relying on nano-level CNC polishing technology.
Everwin Precision: Uses 100% recycled aluminum to manufacture MacBook shells, taking into account lightweight and environmental protection requirements.




3.2 Intelligentization and Digital Empowerment



Industrial 4.0 factory: For example, BYD's "Using iPad to Produce iPad" project uses automated optical inspection (AOI) equipment to achieve real-time defect identification.
Cross-border collaboration: Chinese manufacturers provide online quotation systems and production progress tracking platforms, and European and American customers can remotely monitor order status.




4. Cooperation Guide for European and American Enterprises: How to Select High-Quality Chinese Suppliers?



4.1 Key Evaluation Indicators



Certifications: ISO 9001 (quality management), IATF 16949 (automotive), ISO 13485 (medical).
Equipment list: factories equipped with high-end machine tools such as DMG MORI and MAZAK are preferred.
Intellectual property protection: Sign an NDA agreement and select compliant suppliers that have served Apple, Tesla and other companies.




4.2 Risk Avoidance Strategies



Phased cooperation: Start with small batch trial production (e.g. 500 pieces) to verify quality stability, and then expand to large-scale orders.
Third-party quality inspection: CMM test report and material composition analysis certificate are required.




5. Future Trends: Challenges and Opportunities of Made in China



Challenges: low-cost competition in Southeast Asia, and the "nearshore outsourcing" policy in Europe and the United States (such as the US "CHIP Act").
Opportunities:
High-end technology: China's 5-axis CNC machine tool localization rate is expected to reach 29.2% in 2029, breaking the monopoly of Germany and Japan.
Globalization of services: China-Europe Express and RCEP agreements reduce cross-border logistics costs, and door-to-door time is compressed to 15 days.






Conclusion：
Cook's affirmation of Made in China confirms the core logic of "technological density" replacing "low cost" in the reconstruction of the global industrial chain. For European and American companies, choosing Chinese CNC processing and mold injection molding service providers is not only a cost consideration, but also a strategic investment in precision manufacturing capabilities and supply chain resilience.

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——Unveiling the secrets and application scenarios of the two processes

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In the world of plastic products, blow molding and injection molding are two major molding technologies, but their relationship is often misunderstood. Some people say that "blow molding is a type of injection molding", but in fact, the two are completely different! They are like a pair of "twin flowers". Although they belong to the field of plastic molding, they have their own advantages in principle, application and cost. This article will take you to explore the mysteries of these two processes in depth to help you find the most suitable solution.


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1. Process principle: the game between air and pressure


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Blow Molding
Core principle: Use compressed air to blow the softened plastic parison to fit the inner wall of the mold to form a hollow product.
Steps: Heat the plastic → Extrude the parison → Close the mold and blow air → Cool and shape → Demold and trim.
Key equipment: Blow molding machine, mold, air compressor.
Typical applications: Hollow products such as plastic bottles, fuel tanks, and medical device containers.


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Injection Molding
Core principle: Inject molten plastic into a closed mold at high pressure, and form solid or complex structural parts after cooling.
Steps: molten plastic → high pressure injection → cooling and solidification → demoulding.
Key equipment: injection molding machine, precision mold.
Typical applications: solid or high-precision parts such as mobile phone cases, gears, and auto parts.








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Comparison highlights:

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Blow molding relies on air molding and is suitable for "hollow"; injection molding relies on high-pressure filling and specializes in "solid".
Injection molds require extremely high precision (such as CNC processing), while blow molding molds are more flexible, but are prone to problems such as flash.


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2. The competition between materials and design

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Material selection
Blow molding: commonly used soft plastics (such as HDPE, LDPE, PP), suitable for containers with high flexibility requirements.
Injection molding: compatible with hard plastics (such as ABS, PC, nylon), can add glass fiber to enhance performance.
Design freedom
Blow molding is limited to hollow structures, but can achieve complex curved surfaces (such as bottles with handles).
Injection molding can produce precision parts with details such as threads and bosses, and even multi-color one-piece molding.
Case highlights:
The "star product" of blow molding: carbonated beverage bottles (stretch blow molding technology improves pressure resistance).
The "masterpiece" of injection molding: foldable safety seats (complex structure + high-strength materials).


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3. Trade-off between cost and efficiency

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Initial investment
Blow molding molds are low cost (only one side mold is needed), and the machine price is more affordable.
Injection molds are expensive (precision machining), but suitable for mass production to dilute the cost.
Production cycle
Blow molding is fast for single-piece molding, but post-processing (such as trimming) may increase the time consumption.
Injection molding cycle is stable, and multi-cavity molds can produce dozens of parts at the same time, which is more efficient.
Economic recommendations:
Choose blow molding for small batches of hollow parts (such as customized containers);
Choose injection molding for complex solid parts (such as electronic component housings).


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4. Future Trends: Innovation Drives Process Upgrading

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Blow molding technology:
Multi-layer coextrusion: Improve barrier properties (such as anti-oxidation layer of food packaging).
Biodegradable materials: Respond to environmental protection needs, such as PLA blow molding bottles.
Injection molding technology:
Micro injection molding: Produce millimeter-level precision parts (such as medical catheters).
Smart mold: Integrated sensors monitor pressure and temperature in real time


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5. How to choose? One table to help you choose!

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Comparison Items

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Blow molding

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Injection molding

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Applicable Products

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Hollow containers (bottles, barrels)

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Solid parts (gears, housings)

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Material Type

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Soft plastics (HDPE, PP)

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Hard plastic (ABS, PC)

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Mold Cost

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Low

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High

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Design complexity

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Medium (limited to hollow structures)

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High (supports fine details)

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Production batch

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Small and medium batches

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Large quantities

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Conclusion




Blow molding and injection molding seem similar but each has its own advantages. Whether it is a lightweight mineral water bottle or a precision automotive component, the two technologies work together in a precise manner. When choosing, you need to consider product requirements, cost budget and design goals to maximize benefits.

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In the development of plastic products, choosing between 3D printing and injection molding requires comprehensive consideration of factors such as cost, precision, batch size, and design complexity. The following is an analysis of the two processes from the two core dimensions of cost optimization and high-precision requirements, combined with the characteristics of the two processes, and provides a basis for decision-making.


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1. Cost minimization: How to choose?

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1) Production batches determine the core cost structure


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3D printing: suitable for small batches (usually <1000 pieces) or single-piece production. It does not require mold costs, has low material loss (only the support structure may waste a small amount of material), and is flexible in iteration. For example, when using FDM technology to print a prototype, the cost per piece may be only 1/10 of that of injection molding.


Injection molding: more cost-effective in large-scale (>1000 pieces) production. Although the mold development cost is high (thousands to tens of thousands of yuan), the cost per piece decreases significantly as the batch increases. For example, in one case, the injection mold cost $10,000, but the cost per piece was only $0.1 when producing 100,000 pieces.




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2)Design and iteration cost comparison




3D printing: CAD models can be directly printed after modification, without additional costs, suitable for the prototype stage where the design is frequently adjusted. For example, a company shortened the R&D cycle from 4 weeks to 48 hours by using 3D printing molds.


Injection molding: Mold modification costs are high (especially metal molds), suitable for mass production after the design is finalized. If the mold structure needs to be adjusted, it may be necessary to re-open the mold, which will increase the cost by tens of thousands of yuan.




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3)Material And Post-Processing Costs





3D printing: limited material types (such as PLA, nylon, resin, etc.), some high-performance materials (such as PEEK) are expensive; post-processing usually only requires grinding or sandblasting.


Injection molding: wide selection of materials (such as ABS, PP, PC, etc.), lower prices; but post-processing such as mold polishing and electroplating may increase costs.






Decision suggestions:
Small batch/prototype: choose 3D printing (FDM, SLA or SLS);
Large batch/finalized product: choose injection molding.




2. High-precision requirements: How to make a choice?



1) Process accuracy comparison





3D printing:
SLA/DLP: accuracy of ±0.01 mm, smooth surface, suitable for precision medical or electronic parts.
SLS/MJF: accuracy of ±0.1 mm, suitable for complex structures but slightly rough surface.
FDM: lower accuracy (±0.2 mm), obvious layer pattern, need post-processing.


Injection molding:
accuracy is usually ±0.05 mm, high surface finish (Ra 0.8~1.6 μm), no additional processing required.






2)Material strength and stability




3D printing: weak interlayer bonding, which may affect mechanical properties; easy to deform at high temperatures (such as PLA softening point is 55°C).
Injection molding: The material is dense, high in strength and isotropic, and has better temperature resistance (such as ABS can withstand 80~100°C).






3) Complex structure adaptability




3D printing: It can manufacture complex structures that are difficult to achieve with traditional processes, such as hollowing and conformal water channels. For example, the curved cooling channel in the mold can improve the injection efficiency.

Injection molding: Due to the mold demolding requirements, the design must avoid internal right angles or too deep cavities, otherwise it will increase the difficulty of processing.






Decision suggestions:
High precision + complex design: choose SLA or metal 3D printing (such as SLM), but you need to accept higher costs;
High precision + large batch: injection molding combined with CNC precision mold to ensure dimensional stability.




3. Comprehensive Decision-making Process



Clear requirements: batch, budget, design complexity, precision level, material performance.
Cost accounting: compare mold costs, single-piece material costs and post-processing costs.
Technology matching:
If fast iteration or small batches are required, 3D printing is preferred;
If high strength or surface finish is required, injection molding is preferred.
Hybrid solution: For example, use 3D printing to make prototypes or conformal water channel molds, and then mass produce them through injection molding.




4.Typical Case References



1) Pepsi bottle mold: By combining 3D printed inserts with traditional metal molds, the cost is reduced by 96%, and the production cycle is shortened from 4 weeks to 48 hours.
2) Medical implants: Use SLA to print high-precision prototypes, and then switch to injection molding for mass production after verification.
3) Shoe mold manufacturing: 3D printing can achieve complex patterns, replacing traditional CNC, and increasing efficiency by 50%.




Summary



Between low cost and high precision, a balance needs to be made according to specific scenarios:
3D printing: the first choice for small batches, complex designs, and rapid iterations;
Injection molding: an economical solution for large batches, high precision, and high-strength scenarios.


In the future, hybrid manufacturing (such as 3D printing molds + injection molding mass production) may become the mainstream direction for balancing cost and performance.