Plastic Injection Molding Service

Plastic Injection Molding

Injection molding is a high-volume production procedure for plastic products. Molten material is injected into a mold cavity, allowed to cool and harden before being ejected from the mold. We offer full production services using a variety of injection molding machines and equipment to create plastic components of varied sizes, shapes, and complexities. Our expert professionals oversee the whole manufacturing process to ensure consistency in quality and adherence to standards.

Plastic Injection Molding Capabilities

With advanced technology and a skilled team, we excel in solving customer's problems and molds needs. Developing new projects and using creative thinking and innovation allows us to provide excellent service. Meeting our client’s expectations when it comes to quality, service, and end products has always been imperative.

Injection Molding

An integral part of our business is injection molding, which need utmost precision and high standards of efficiency in order for the outcome to be considered a quality plastic component. We have various injection molding machines and different tonnages that enable us to operate in a broad spectrum of the longer and more complex parts for molding. Be it small, sophisticated components or large structural parts, we are capable of delivering quality results every time.

Overmolding

Overmolding is a technique where one material is molded over another material to form a single cohesive structure. Different materials, colors, textures can be used together for enhanced product durability, functionalities and aesthetics. This ergonomic processing method is done for grip handles, seals and multi-component parts.

Insert Molding

Insert molding is another specialized molding process where pre-formed components, such as metal inserts or other materials, are placed into the mold before the injection of molten plastic. This process allows for the integration of multiple materials in a single, cohesive part, enhancing strength, functionality and design flexibility. Insert molding is commonly used in applications such as threaded fasteners, electrical connectors and medical devices.

Two-Shot Molding

Two-shot molding, also known as dual-shot or multi-shot molding, is a versatile molding process that allows for the sequential injection of two different materials or colors into a single mold. This process enables the creation of complex, multi-color or multi-material parts with precision and efficiency. Two-shot molding is commonly used in applications such as automotive interiors, consumer electronics, and medical devices.

Secondary Operations

Surface Painting

Painting is a secondary operation often employed to add color, decorative finishes or protective coatings to injection molded parts. Customized Pantone or RAL color available according to requirement.

Printing and labeling

Printing and labeling operations are used to add graphics, logos, instructions or product information onto the surface of molded parts. Various printing techniques such as pad printing,screen printing and hot stamping can be employed to transfer ink onto the part surface accurately. Labels or decals may also be applied using adhesive backing.
Product identification and differentiation, the communication of important information, and branding are all aided by printing and labeling.

Electroplating

Electroplating is a surface finishing method used to apply a thin layer of metal to the surface of injection-molded products. This process enhances the conductivity, durability, and aesthetics of the parts in addition to giving them resistance to corrosion. Gold, copper, nickel, and chromium are often used metals for electroplating. Electroplating can provide visually appealing surfaces in addition to increasing wear resistance and enabling electrical conductivity for useful applications.

Ultrasonic Welding

Ultrasonic welding, which makes use of high-frequency ultrasonic vibrations, is a rapid and efficient method of joining thermoplastic components. By creating a strong, hermetic bond between components, this technique does away with the need for adhesives or other fasteners.

Common Injection Molding Materials

The material used for injection molding is determined by criteria such as the desired qualities of the finished product, application requirements, and cost. The following are some of the most frequent materials used in injection molding.

Material	Feature	Common Applications
Acrylonitrile Butadiene Styrene (ABS)	High Stability and impact-resistant	automotive parts, electronics, consumer goods and appliances.
Polypropylene (PP)	high stiffness, chemical resistance and heat resistance	packaging,automotive components,household products and medical devices
Acetal (Polyoxymethylene, POM)	stability, low friction and wear resistance.	gears, bearings and sliding components
Polycarbonate-ABS Blends (PC-ABS)	high-temperature resistance and impact strength	automotive interiors, electronics housings and consumer goods
Polyetheretherketone (PEEK)	high strength, stiffness and heat resistance	aerospace components, medical implants and oil and gas equipment.
Polycarbonate (PC)	high impact strength, heat resistance, and optical clarity	automotive headlamps, electronic components and medical devices
Polyamide (PA) - Nylon	high strength, toughness, and wear resistance	gears, bearings, bushings, automotive parts and industrial components.
Polystyrene (PS)	clarity, rigidity and ease of processing	packaging, consumer goods, disposable utensils and toys
Polyethylene (PE)	Lightweight,chemical resistance and low moisture absorption	packaging, containers, toys and household products.

Why Choose Rex for Your Project Production

Rex's design and prototype verification, tool design and production, surface finishing, and assembly services create a complete package. We always prioritize providing customized solutions, exceptional quality, and reliable service, therefore, exceeding customer expectations.

Extensive Experience

Establishing Rex’s name in the market was made possible because of our more than two decades of experience in plastic injection molding. A trustful and reliable manufacturer like Rex is at your fingertips because of our expert team who has the knowledge, skills, and expertise to take a product from prototyping to mass production and dominate the market swiftly.

Cost-Effective Solutions

Rex understands that every client has unique goals and objectives which may involve operating under a specific budget. To help our customers achieve their financial goals without sacrificing the quality of the output, we optimize production processes by minimizing waste and maximizing efficiency.

Quality Assurance

Alongside economic goals are quality assurance goals. Quality is central at Rex. Adhering to economical guarantees alongside our core goal of brand identity enables us to implement strict quality control measures to ensure every produced part meets the set standards. Rex is devoted to provide top-level products from material selection to final inspection.

On-time Delivery

We guarantee that your projects are finished on time and delivered in accordance with your timelines by using effective procedures, cutting-edge technology, and an emphasis on planning and logistics.

Advantages of Plastic Injection Molding

The plastic molding process is commonly used because it offers a range of benefits. Some of these benefits include its efficiency, cost-effectiveness, and flexibility in design.

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High Efficiency and Productivity

Injection molding enables the production of identical components with minimal control cycles. Depending on the part’s size and complexity, thousands to millions of parts can be manufactured on a daily basis, enabling long periods of automation. In addition, large-scale production of identical components is simplified due to shorter cycle times in production.
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Cost-Effectiveness

Creating the necessary molds requires high initial investment, but once this is achieved, injection molding becomes extremely cost-effective for mass production of components. The more products manufactured, the lower the cost becomes per single part. Due to these appealing qualities, injection molding enables manufacturers to achieve higher production rates and scale.
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Design Flexibility

Extensive design flexibility is available with injection molding, meaning there are no geometrical restrictions for custom features in parts. Integrated approaches allow for design changes to be implemented with ease, resulting in simpler assembly steps and overall product architecture.
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Minimized Waste of Materials

When it comes to material waste, injection molding has a clear advantage compared to other manufacturing processes. Any excess material from runners and sprues is able to be stuffed and cost-effective, also lessening the impact on the environment.
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Surface Finish Options

The surface finish of parts produced by injection molding can be smooth, textured, matte, glossy, or any form of custom designs. These surface finish options can be applied directly from the injection mold, or can be achieved through secondary processes like painting, coating or plating.
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Enhanced Part Properties

The use of injection molding enables the use of multi-material overmolding, fillers, additives, reinforcements or other methods to improve impact resistance, thermal, or electrical conductivity of the object being molded.
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Short Lead Times

When compared to other methods, injection molding possesses relatively shorter periods from design and manufacturing. After a mold is produced, mass production can start immediately, meaning that prototypes, product developments, and time-to-market can be done faster.
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Automation and Process Control

The injection molding process is automated to a high degree, and advanced control systems supervise and adjust certain characteristics including temperature, pressure, and even injection speed. This guarantees that all parts produced are of equal quality, minimizes error, and increases production speed.