What Is Injection Molding Rapid Tooling?

Step-by-Step Guide to Placing an Order with Your Own Mold



Thank you for choosing F&Q-Tech for your injection molding needs. If you have your own mold, please follow the steps below to place an order with us. If you have any questions at any stage, feel free to contact our support team at lyy@fsqj-tech.com.





Step 1: Verify Your Mold Specifications



Before placing an order, please ensure that your mold meets the following specifications:
• Material Compatibility: Confirm that the mold is suitable for the type of plastic material you intend to use.
• Mold Dimensions: Verify that the mold dimensions match your product requirements.
• Mold Condition: Ensure that the mold is in good condition and ready for production.
If you need assistance with mold verification, please contact our technical team at lyy@fsqj-tech.com.




Step 2: Submit Your Mold



Once you have verified your mold specifications, please send your mold to our facility. You can choose to:
• Ship the Mold: Use a reliable courier service to ship the mold to our address:
[Please contact our team (lyy@fsqj-tech.com) for an address]

Please include your contact information and order details inside the package.
• Deliver the Mold In-Person: If you prefer to deliver the mold in person, please schedule a drop-off time with our logistics team at [lyy@fsqj-tech.com].

Please ensure that your mold is securely packaged to prevent any damage during transit.




Step 3: Confirm Order Details



After we receive your mold, our team will inspect it and confirm the order details with you. Please provide the following information:
• Product Quantity: Specify the number of units you wish to produce.
• Material Type: Indicate the type of plastic material you want to use (e.g., ABS, PC, PP).
• Color Requirements: Specify any color preferences or Pantone codes.
• Surface Finish: Indicate any specific surface finish requirements (e.g., glossy, matte).
• Delivery Date: Provide your desired delivery date.
You can submit this information via email to [lyy@fsqj-tech.com] .




Step 4: Review and Approve Quotation



Based on the information you provide, we will generate a detailed quotation for your order. The quotation will include:
• Mold Setup Fees: Any fees associated with setting up your mold.
• Production Costs: Costs based on the number of units and material type.
• Shipping Costs: Estimated shipping fees to your desired location.
Once the quotation is ready, we will send it to you for review. Please review the details and confirm your approval by replying to the email




Step 5: Production and Quality Check



After you approve the quotation, we will begin the production process. Our team will:
• Set Up Your Mold: Prepare the mold for production.
• Start Production: Begin injection molding your products.
• Conduct Quality Checks: Perform thorough quality checks to ensure your products meet the required standards.
If you have any specific quality requirements, please inform us during the order confirmation stage.




Step 6: Delivery and Feedback



Once production is complete and quality checks are passed, we will arrange for the delivery of your products. You can choose from the following delivery options:
• Ship to Your Address: We will ship the products to your specified address.
• Pick Up at Our Facility: You can arrange to pick up the products at our facility.
After you receive your order, we would appreciate your feedback. Please let us know if you have any comments or suggestions by contacting us at email.




Contact Information



For any questions or assistance throughout the ordering process, please contact us:
Email: [lyy@fsqj-tech.com]
WhatsApp: [+86 136 1605 5490]




Additional Notes



• Mold Storage: If you plan to place future orders using the same mold, we offer mold storage services. Please inquire about this option during the order process.
• Rush Orders: If you need a rush order, please inform us as soon as possible so we can accommodate your request.

This guide should help your customers understand the process of placing an order with their own molds and ensure a smooth and efficient transaction.

Step-by-Step Guide to Ordering with Custom Mold Requirements




Thank you for choosing F&Q-Tech for your injection molding needs. If you do not have an existing mold but have product drawings or samples, please follow the steps below to initiate the process of creating a custom mold and placing an order. If you have any questions at any stage, feel free to contact our support team at [ lyy@fsqj-tech.com].




Step 1: Provide Your Product Details



To begin the process, please provide us with the following details:
· Product Drawings: CAD files or detailed technical drawings of the product you want to produce.
· Preferred formats: .dwg, .dxf, .step, .iges, or .pdf.
· Samples: If you have a physical sample, please send it to us for analysis.
· Shipping Address: [Your Company Name, Your Company Address, City, State, ZIP Code, Country].
· Material Requirements: Specify the type of plastic material you want to use (e.g., ABS, PC, PP).
· Quantity: Indicate the number of units you wish to produce.
· Color and Finish: Specify any color preferences or Pantone codes, and any specific surface finish requirements (e.g., glossy, matte).
You can submit this information via email to [lyy@fsqj-tech.com].




Step 2: Review and Quotation



Once we receive your product details, our engineering team will review the information and assess the feasibility of the mold design. We will then provide you with a detailed quotation that includes:
· Mold Design and Manufacturing Costs: The cost associated with designing and manufacturing the custom mold.
· Production Costs: Costs based on the number of units, material type, and other specifications.
· Shipping Costs: Estimated shipping fees to your desired location.
The quotation will be sent to you within [1-3] business days. Please review it carefully and confirm your approval by replying to the email.




Step 3: Mold Design and Approval



After you approve the quotation, our design team will create a 3D model of the mold. We will send you the design for your review and approval. Please check the following:
· Design Accuracy: Ensure that the mold design matches your product requirements.
· Dimensions and Tolerances: Verify that all dimensions and tolerances are as specified.
· Any Modifications: Let us know if any modifications are needed.
Please review the design within [1-3] days and provide feedback or approval. Delays in approval may affect the production timeline.




Step 4: Mold Manufacturing



Once the mold design is approved, we will begin the manufacturing process. Our skilled technicians will:
· Machine the Mold: Use advanced machinery to fabricate the mold.
· Conduct Quality Checks: Perform thorough quality checks to ensure the mold meets the required standards.
· Test the Mold: Conduct test runs to ensure the mold functions correctly and produces parts to specification.
The mold manufacturing process typically takes [5] weeks. We will keep you updated on the progress.




Step 5: Production and Quality Assurance



With the mold ready, we will proceed to production. Our team will:
· Set Up the Mold: Install the mold in our injection molding machines.
· Start Production: Begin the injection molding process to produce your parts.
· Conduct Quality Assurance: Perform quality checks on the produced parts to ensure they meet your specifications.
If you have any specific quality requirements, please inform us during the order confirmation stage.




Step 6: Delivery and Feedback



Once production is complete and quality checks are passed, we will arrange for the delivery of your products. You can choose from the following delivery options:
· Ship to Your Address: We will ship the products to your specified address.
· Pick Up at Our Facility: You can arrange to pick up the products at our facility.
After you receive your order, we would appreciate your feedback. Please let us know if you have any comments or suggestions by contacting us at [ lyy@fsqj-tech.com].




Contact Information



For any questions or assistance throughout the ordering process, please contact us:
· Email: [lyy@fsqj-tech.com]
· Tel / WhatsApp:[+86 136 1605 5490]




Additional Notes



· Mold Storage: If you plan to place future orders using the same mold, we offer mold storage services. Please inquire about this option during the order process.
· Rush Orders: If you need a rush order, please inform us as soon as possible so we can accommodate your request.

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 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.

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The science of injection molding machine tonnage: the watershed between small tonnage and large tonnage

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In the field of plastic injection molding, the "tonnage" of an injection molding machine directly determines its capacity limit. Tonnage does not refer to the weight of the entire machine, but the size of its clamping force, measured in tons (T). This parameter represents the maximum closing force that the clamping system of the injection molding machine can exert, which is used to resist the huge expansion pressure generated when the molten plastic is injected into the mold. If the clamping force is insufficient, the mold will be stretched open, resulting in flash burrs; and excessive tonnage will cause energy waste and equipment loss.
The calculation of clamping force follows the core formula:
Clamping force (T) = product projection area (cm²) × mold pressure (kg/cm²) × safety factor / 1000
The mold pressure depends on the material properties:
Ordinary plastics (such as PP, PE): 250-350 kg/cm²
Engineering plastics (such as PC, nylon): 350-500 kg/cm²

The safety factor is usually 1.1-1.2.


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1. The core differences between injection molding machines of different tonnages

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Injection molding machines can be divided into four categories according to tonnage, which have significant differences in mechanical structure, application scenarios and technical requirements:
（1）Small machine (30-100 tons)
Structural features: mostly vertical or angular design, mainly fully electric drive, small footprint
Injection volume: usually ≤200 grams (based on PE)
Typical applications:
Electronic connectors (USB interface, SIM card tray)
Precision gears (clocks, micro motor parts)
Medical equipment (syringe needles, test tubes)

Advantages: high precision (repeat error ±0.01mm), energy saving (60% less power than hydraulic presses), no oil pollution
（2）Medium-sized machine (150-500 tons)
Mainstream machine: hydraulic or hydraulic-electric hybrid drive, horizontal structure
Injection volume: 300-2000 grams
Application scenarios:
Household appliance housing (rice cooker, vacuum cleaner housing)
Daily necessities (washbasin, chair, toy)
Automotive interior parts (dashboard frame, door handle)
Technical highlights: Can be equipped with multi-color injection molding system (such as P-type/L-type double shot) to achieve dual-material composite molding
（3）Large machine (600-1000 tons)
Structural features: two-plate clamping mechanism, enhanced rigidity and mold opening space
Injection volume: 2500-5000 grams
Typical products:
Logistics pallet (1200×800mm standard size)
Automobile bumper
Large trash can
Challenge: Need to cooperate with mold temperature control system to prevent shrinkage of thick-walled parts
（4）Ultra-large machine (>1000 tons)
Representative models: Haitian 1600T, Fuqiangxin 1900T three-color machine
Capacity indicators: up to 4000 tons, injection volume exceeds 20kg
Application areas:
Automobile instrument panel (one-piece molding)
Yacht deck parts
Large turnover box (volume>1000L)
Innovative design: horizontal two-color machine (H type) with overlapping mold technology, production capacity increased by 70%



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Table: Comparison of injection molding machine tonnage and key parameters


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Tonnage range

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Clamping force (T)

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Injection volume (g)

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Screw diameter(mm)

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Typical mold structure

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Minicomputer


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30-100

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≤200

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25-40

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Toggle

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Medium-sized machine


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150-500

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300-2000

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45-70

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Toggle/Two-Plank

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Mainframe


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600-1000

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2500-5000

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75-110

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Two-plate

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Large Scale Machines


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>1000

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>5000

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≥120

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Two-plate enhanced



2. Core principles and application scenarios of tonnage selection



The cost of failed selection
Insufficient tonnage: product flash and size deviation (a mold that is stretched 0.1mm can lead to scrapping)
Tonnage is too large: energy consumption increases by 30%-50%, the risk of mold deformation increases, and mold exhaust difficulties lead to burning




Four-step scientific selection method
Calculate clamping force
Take the car bumper as an example: the projected area is 1200×600mm=7200cm², and the pressure in the PC mold is 400kg/cm²
Theoretical clamping force = 7200×400×1.2/1000≈3456T → Select the 3500T model
Test tolerance
Mold size ≤ tie rod spacing (such as the tie rod spacing of the 1000T machine is usually 1200×1200mm)
Mold thickness ∈ [minimum mold thickness, maximum mold thickness] (for example: the mold thickness range of 350T machine is 150-450mm)
Ensure demoulding space
Mold opening stroke needs to be > product height×2 + runner length (deep cavity parts need to add an additional 20% margin)
Match injection system
Finished product weight should be ≤ Theoretical shot volume × 75% (leave a safety margin)
For thin-walled parts, choose a small screw (high pressure and high speed), and for thick-walled parts, choose a large screw (high plasticizing capacity)
Industry scenario application
Electronic industry (below 100T): Connectors use a 30mm diameter screw, and the shot speed ≥300mm/s ensures filling
Home appliance industry (300-800T): Air-conditioning panels use hot runner molds + 650T machines to reduce runner waste
Automotive industry (>1000T): Door panels use a double-station turntable three-color machine to achieve one-time molding of substrate + soft glue + logo
Medical industry (50T fully electric): Syringe production is equipped with a Class 100 clean room to avoid hydraulic oil pollution




3. Future trends in technology evolution and tonnage selection



The selection of injection molding machine tonnage is undergoing three major technological changes:
Energy-saving drive
All-electric injection molding machines (such as FANUC Roboshot) replace hydraulic presses below 100T, reducing energy consumption by 60%; the penetration rate of hybrid technology in large machines increases (such as Haitian MA series)
Intelligent control system
IoT module monitors clamping parallelism in real time (deviation of >1000T machine needs to be ≤0.1mm/m)
AI algorithm dynamically optimizes the pressure holding curve, reducing the molding cycle of large-tonnage machines by 15%
Specialized development
Micro injection molding machine (<10T): used for medical microfluidic chips, injection accuracy ±0.002g
Multi-component large machine: such as Fuqiangxin FB-1900R three-color machine, turntable diameter 2250mm, serving the integrated molding of automobile lampshades

In the future, with the application of new materials (such as carbon fiber reinforced plastics), the clamping accuracy requirements for high-tonnage machines will be further improved, and modular design will make tonnage adjustment more flexible-by replacing the screw assembly, the same clamping unit can cover the injection range of ±30%.




4. Conclusion



The selection of injection molding machine tonnage is like deploying troops for a battle: too little will not be enough, and too much will be a waste of money and effort. From a connector the size of a fingernail to a car bumper several meters long, the difference in tonnage is the result of the deep collaboration of material science, mechanical design, and control algorithms. In the future, with the advancement of energy-saving technology and intelligence, tonnage selection will no longer be based solely on empirical formulas, but will be dynamically optimized based on real-time data, pushing plastic molding into a new era of "tailor-made".