Mold Manufacturing

Professional Injection Molding for Plastic

Injection molds are made to produce plastic with exact dimensions and full structures. Rex is the greatest option if you require injection molds. We are certain that we can offer the ideal solution for your molding needs thanks to our many years of experience and excellent manufacturing techniques.

Rex is primarily concerned with injection mold design and production. Every mold we create is subjected to the strictest quality and precision requirements thanks to the hard efforts of our team of highly qualified engineers and technicians. We take pleasure in offering molds that go above and beyond for our clients because we recognize how crucial dependable, effective molds are to the production process.

With the help of cutting-edge equipment and technology, our workshop can create molds of any size and complexity. Whether you require a basic mold for small-scale manufacture or a sophisticated mold for large-scale production, we can accommodate your needs. Your job will be handled expertly by Rex because of our experience and dedication to quality.

Different Molds Making Services

Whether you're starting a one-off project or need dependable production tooling for small batches, our quick lead times and adherence to international standards make us the first choice. Our skilled team specializes in creating custom injection molds from appropriate materials, guaranteeing quality consistency and repeatability. From silicone rubber injection molding to overmolding, insert molding, thermoplastic injection molding, liquid silicone injection molding, hot runner molding, and cold runner molding, we offer a wide range of services that will make your projects stand out.

Double-color Injection Molds

The double color injection molds make it possible to produce parts from two different colors and/or materials creating another level of innovation and flexibility in manufacturing. Double-color injection molding is the process of injecting two different types of plastic into one injection mold to create an item that comes in two or more colors. This process is executed in two steps to form a single, fully colored unit with superb color harmony. The beauty of it is that the parts can be produced with elaborate configurations and attractive designs that will beautify the item.

Insert Molds

A pre-formed part, frequently composed of metal or another material, is inserted (put) into the mold prior to the injection of molten plastic in insert molding, a specialized injection molding technique. A single integrated product is then produced by molding the plastic over or around the inserted component. The advantages of plastic and metal or other materials are frequently combined in a single, intricate component using this technique.

Double-color Injection Molds

In the realm of double colors injection molding, there are two different molds

Rotary Two-Color Injection Molding

Often used to combine the benefits of both plastic and metal (or other materials) into a single, complex part, insert molding is a specialized injection molding technique in which a pre-formed component, usually made of metal or another material, is placed into the mold before molten plastic is injected. The plastic is then molded around or over the inserted component, creating a single, cohesive product.

Secondary Injection Molding/Overmolding

This technique involves the independent injection of two different plastic polymers in two stages. Products are first molded with a single set of molds. After being molded, these items are taken out and put into a different set of molds for the second injection molding procedure. Despite requiring two sets of molds, this method has the advantage of flexibility because it does not require a special double-color injection molding equipment.

Applications

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Double-color injection molding's adaptability has been used in a variety of industries, such as the automotive sector to improve exterior and interior components with eye-catching color combinations; the electronics sector to elevate the design of electronic devices with two-tone aesthetics; the medical field to add a touch of sophistication to medical equipment and devices; the home appliance sector to create visually striking and contemporary household products; the toy industry to add excitement and vibrancy; and the cosmetics sector to create distinctive and eye-catching packaging for cosmetic products.

Advantages of Double Colors Injection Molding

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Versatility Adaptable to a variety of industries, offering product designers a flexible solution;
Enhanced Durability Combining materials with different properties can improve the final product's overall durability and functionality;
Reduced Assembly Steps This streamlines the production process by doing away with the need for separate assembly steps for multicolored components;
Aesthetic Appeal The ability to seamlessly use two colors or materials opens up countless design possibilities and gives products a touch of elegance.

Whether choosing the flexibility of secondary injection molding or the accuracy of rotary two-color injection molding, manufacturers can achieve stunning results that appeal to consumers across a variety of industries. Double colors injection molding is a visionary approach to manufacturing that combines creativity and precision to produce products that stand out in terms of both functionality and aesthetics.

Insert Molds

Key features of insert molding

Versatility: When developing complex items, insert molding offers the ability to combine various materials and components.
Strength and Durability: BIncreased Insert molding can improve the final product's strength, durability, and functionality by adding metal or other materials to the molded portion.

Decreased Assembly Steps: By integrating parts throughout the molding process, extra assembly steps are not necessary, which simplifies manufacturing and lowers labor expenses.

Cost-effective:Because it eliminates the need for additional assembly procedures, insert molding, in spite of its complexity, can be a cost-effective solution.

Electrical connectors, bushings, threaded fasteners, metal inserts in plastic handles, and other parts where it is beneficial to combine dissimilar materials are common uses for insert molding. By carefully integrating various materials in a single molding process, insert molding is a technology that makes it possible to create intricate and long-lasting pieces.

Mold Manufacturing Processes

Content of Project Analysis

Material Analysis for Injection Molding

Explore material details such as name, brand, and manufacturer. Discover important material information that affects the injection molding process and subsequent post-processing steps.

Structural Analysis for Mold Manufacturing

Analyse product shape, tolerance, technical specifications, surface specifications, and draft angles. Comprehensive structural analysis is very beneficial in mold manufacturing and minimizes complications throughout the processing stages.

Wall Thickness Assessment

Analyze wall thickness to address considerations related to shrinkage and product strength.The best wall thickness choices help to minimize shrinkage problems and ensure product durability.

Product Assembly Analysis

Examine the complexities of product assembly to inform gate placement choices and address localized shrinkage issues. Insightful analysis directs gate position selection and effectively addresses shrinkage issues.

Confirmation of Final Product and Mold Files

Examine and confirm the final product file and matching mold file carefully to wrap up the process.This guarantees precision, thoroughness, and preparedness for the following production phases.

Why Need To Build A Plastic Injection Mold

Plastic injection mold making is vital for numerous reasons in the manufacturing industry

Manufacturing in Large Quantities

Precision and consistent quality in the mass production of plastic components are made possible by injection molding. Making molds enables producers to mass-produce intricate designs and complex features.

Economical Effectiveness

Even though creating a mold can require a large initial investment, high-volume production greatly reduces the cost per unit. Once made, the mold can be utilized for several production cycles, which lowers the cost of the manufacturing process as a whole.

Design Adaptability

Manufacturers can create parts with complex geometries and fine details thanks to the design flexibility provided by injection moulds. In order to meet specific product requirements and achieve desired shapes, this versatility is essential.

High Precision

Injection molding produces plastic components with high precision and accuracy; the molds guarantee that each part satisfies the exact specifications and tolerances needed for the final product.

Consistency

The use of molds ensures consistent quality across all produced parts, which is essential for maintaining product standards and meeting customer expectations; Rapid Prototyping.

Injection mold making allows for the rapid prototyping of plastic parts, allowing manufacturers to test and refine designs prior to committing to full-scale production, reducing the risk of errors and design flaws.

Material Efficiency

Since injection molding is a closed-loop process, it uses less material than other manufacturing techniques, minimizing material waste; reduced Labor Intensity.

Minimized Labor Intensity

After the mold is set up, the injection molding process requires very little labor, which helps with large-scale production efficiency and cost savings.

In conclusion, creating plastic injection molds is essential to obtaining high-volume, cost-effective production of plastic components with accuracy, consistency, and design flexibility across sectors.

Components Of Injection Molds

In order to create plastic items and parts, injection molds are sophisticated instruments. They are composed of multiple parts that combine to produce and shape the finished product. The essential parts of injection molds are as follows:

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Mold Base

The mold base serves as the foundational framework for plastic injection molds. Usually, it can be ordered directly from the standard mold manufacturer, it greatly saving the time.
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Cavity(A side)

The cavity, also known as the A-side or mold cavity, is one of the main halves of the mold. It contains the cavity or impression of the final product and determines the outer shape and surface finish.
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Cavity(B side)

The core plate, also known as the B-side or mold core, is the other main half of the mold. It contains the core or impression of the final product and determines the inner shape. The core plate and cavity plate come together to create the mold cavity.
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Sprue Bushing

It is the sprue bushing that allows molten material, typically plastic, to enter the mold chamber. It controls the flow of material and joins the machine nozzle to the mold.
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System Runner

The runner system directs the molten material from the sprue to the mold cavity via channels or passageways. During injection, runners disperse the substance and aid in regulating the flow and pressure.
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The Gates

Gates are holes that allow molten material from the runner system to enter the mold chamber. They regulate the material flow and are positioned carefully to prevent flaws in the finished product.
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Ejector Pins

Located on the side of the mold opposite the cavity, ejector pins are used to push the finished product out of the mold once the material has solidified.
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Slides and Lifters

Lifters and slides are movable parts that produce complex features or undercuts in the final product; they move within the mold to enable the ejection of parts with intricate geometries.
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Guide Pins and Bushings

These components help maintain precision during the injection molding process by ensuring proper alignment and closure of the mold halves.
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Cooling System

Channels or passages within the mold allow for the circulation of cooling fluid (typically water) to dissipate heat and facilitate the solidification of the molten material. Proper cooling is crucial for cycle time and part quality.
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Cavity Inserts

Cavity inserts are replaceable components that allow for flexibility in changing the geometry of the mold for different product designs without replacing the entire mold.

These components work in concert to create the desired plastic part or product during the injection molding process. The design and precision of each component contribute to the quality, efficiency and repeatability of the manufacturing process.

Injection Molds Services Finishes

The finishes on injection-molded parts can vary based on factors such as material, mold design and post-processing.

Here are some common finishes for injection-molded parts

Finish	SPI Standard	Description	Surface roughness(Ra Value)
High Glossy Finish	A2	3000 Grit diamond buff	1-2
Normal Glossy Finish	A3	1200 Grit diamond buff	2-3
Fine Semi Glossy Finish	B1	600 Grit paper	2-3
Medium Semi Glossy Finish	B2	400 Grit Paper	4-5
Normal Semi Glossy Finish	B3	320 Grit Paper	9-10
Fine Matte Finish	C1	600 Grit Stone	10-12
Medium Matte Finish	C2	400 Grit Stone	25-28
Normal Matte Finish	C3	320 Grit Stone	38-42
Texture Finish	MT (MoldTech)
Texture Finish	VDI