RSP: Custom Plastic Injection Molding

Plastic Molding

RSP offers high quality custom plastic injection molding to bring your vision to life. Whether you need to create a fully functional prototype or large volume production, we can make it happen.

Integrating 50+ years of manufacturing knowledge with current best practices and technology, we offer a variety of molding services and value-added processes to meet all of your needs, from single components to full custom turnkey manufacturing.

Our state of the art plastic molding and assembly facility in China provides affordable tooling and molding while meeting the United States’ manufacturing practices and quality standards. We take pride in our socially responsible and environmentally friendly facilities.

Plastic Molding Manufacturing at China Location
This operator is running one our plastic molding machines at one of our facilities located in China.

Plastic Capabilities

We built our facilities to seamlessly integrate a variety of our customers’ custom plastic molding needs. From full engineering, product development support to efficient manufacturing, we offer our customers significant cost savings and additional benefits over our competitors. These include: lower costs, decreased set-up times, high-quality and precision.

Here are a few capabilities we are proud to specialize in:

  • Sonic welding & gluing
  • CNC surface grinding
  • Naturally balanced runners
  • Face-mounted inserts
  • Quick mold change systems
  • Thermoplastic engineering materials

Our cross-functional experience allows us to assist all customers in meeting their plastic and manufacturing objectives. We have experience with the following industries:

  • Telecommunications
  • Consumer
  • Industrial
  • Lighting
  • Housewares
  • Medical
  • Agricultural
  • Automotive
RSP: Plastic Injection Process: From Pellets to Product

Injection Process: From Pellets to Product

Turning plastic pellets into a perfect molded product is what we do best. It may sound like a fairly simple process, but details are everything when it comes to the plastic mold injection process. Here is a quick and simple overview of how we take your design from pellets to product.

The first stage of the process begins by feeding dry plastic pellets, held in a “hopper”, into a heating cylinder by using a hydraulic pump, motor and gears. Within the cylinder there are multiple heating zones which systematically increase the temperature of the material as it moves closer to the gate where it is injected into the tool. Each heating zone is constantly monitored and adjusted. The peak temperature of the plastic depends on the combination of materials being injected, but can reach as high as 725° F. Here at RSP, our average melting temperature of materials is 525°F.

With the help of a stationary and movable platen, the mold is held in place as a nozzle prepares to inject the molten plastic. Next, a clamp mechanism closes the mold halves. The action is performed by a motor rated by the maximum amount of force the machine is capable of creating. Then, the molten plastic is injected into the mold as the clamp keeps the mold closed. As the product solidifies and cools down, the finished product is ejected from the mold.

RSP: Plastic Mold Injection Process
Plastic Mold Injection Process

As discussed above, the typical injection molding machine consists of five major components:

  • Hopper
  • Heating Cylinder
  • Hydraulic Pump, Motor and Gears
  • Stationary & Movable Patens
  • Clamp

In-Mold Decoration

For some projects, there may be a need for In-Mold Decoration (IMD) to include an image or coating on a plastic surface. This process involves printing a high-quality image on a heat resistant plastic film that will hold up to the stress of in-molding. The printed film is inserted into the open plastic injection mold and held in place via vacuum ports or electrostatic charge while the mold is closed. Once closed, plastic resin is injected into the mold, thus encapsulating the label to the finished part. Combining the decoration process with the molding process adds durability, decreases manufacturing costs by eliminating post-molding labeling, handling and storage, and also allows for design flexibility. IMD allows for a wide range of colors, effects, textures, graphic options and can replicate stainless steel, wood grains and carbon fiber. IMD is commonly used used on washers and dryers because of its affordability and durability.

RSP: In-Mold Decoration - Image or Coating

A Seamless Process

In order to provide a low-cost product with minimal set-up, quality and precision, we practice a seamless process to get the job done right the first time. If you are interested in our plastic injection molding, in order to start the project off on the right foot, please provide the following.

1. Request a Quote
2. Provide Drawings/Files

To ensure the integrity of your product, we recommend providing drawings/files in any of the following:

  • IGS/STEP/STP (preferred format)
  • Solidworks
  • AutoCAD
  • Pro-E

If the above file formats are not available, we can produce a model from your sketch or drawing.

Once each party agrees RSP is the best partner for the project, an official order can be placed. This will then launch the design for manufacturing review where we consider all the best practices of molding and design to optimize the model. Once design suggestions are discussed, the engineer team at RSP begins the creation of a 3D model of the tooling This 3D model will need to be approved by you before proceeding further, ensuring your quality standards are being met every step of the way. You can expect to receive weekly updates on tooling status including photos during the tooling phase of your order.

A few other things to note:

RSP offers affordable quick turn prototypes. We create prototypes using machined blocks of plastic for the highest quality and strength. RSP also has 3D printing available for some sizes and shapes.
If you need to bridge the gap between prototyping and production, we offer several options. Our customers can select from aluminum or softer steel tools which allow for lower cost tooling and an easier and quicker turnaround. Softer steel and aluminum molds have a limited life of 5,000-50,000 pcs depending on the design.
Our mold transfer program makes it simple for you to seamlessly transfer your tools to us. After an initial assessment, we will be able to determine if there is a need for additional equipment or safety stock. Everything will be put into writing to protect the interests of all companies involved.
Because we work with custom projects across many, many industries, we cannot guarantee a standard lead time. Please give us a call or request a quote to get an estimated lead time for your project. Typically, our lead times are 4-6 weeks for standard tooling depending on the complexity of the tool. We are generally faster than others in the industry.

Machine & Material Specifics

Looking to see what machines, materials and inspection devices we use? Check out our machine & material specifics page.

Video: RSP Plastic Injection Molding

RSP plastic molding department Shenzhen, China.