Injection Moulding
Our capacity allows us to handle high volumes of millions of components. We scale production to meet your needs, from prototypes to full-scale production. We have more than 100 automated injection molding machines in the group's production. Manufacturing takes place as close to you as possible to minimize transportation.
Low volumes and high volumes – we have the capacity!
Superior Quality at Every Step
At Prototal, we specialize in providing secure injection molding services with the right quality. Before manufacturing begins, we simulate the injection molding process to detect potential issues and risks with the design early on. Then, the tool is designed, and you receive access to trial samples and protocols. We continue to measure and control throughout the entire manufacturing process to ensure consistent quality. We are experienced in working with risk analyses, control plans, and PPAP. We have a controlled CMM measuring machine as well as a 3D scanner and X-ray equipment within our group.
Don't hesitate to contact us for more information or to discuss your unique project needs.
Further processing
2K Injection Molding: The number of components determines the choice between manual or true double injection. Soft, ergonomic grip surfaces are one of the most common applications of this method.
IML – In-Mold Labeling: A decorative label is placed in the mold tool using a robot. After injection molding, the label becomes an integrated part of the final product.
Assembly: We perform assembly tasks such as various types of threaded inserts. It can also involve different types of sub-assembly or packaging before delivery.
Printing: We work with several methods, including pad printing, digital printing, and heat embossing. Printing can be done in-line or as a post-process.
Ultrasonic welding: The choice of thermoplastic, geometry, and energy director design are some of the factors that affect the quality of the welded result. A correctly executed weld provides a joint that is stronger than the surrounding material.
FAQs
- We have a large stock of standard materials. They are all thermoplastics.
- We can order unique materials for each project.
- We work with virtually all available thermoplastics.
- Coloring with masterbatch or compounding.
- Wide range of materials with different properties.
- Short cycle time per item = quickly large volumes.
- Very good process repeatability.
Yes, at Prototal, you can choose from several different processing options to further refine your injection-molded components.
- 2K Injection Molding: The number of components determines the choice between manual or true double injection. Soft, ergonomic grip surfaces are one of the most common applications of this method.
- IML – In-Mold Labeling: A decorative label is placed in the mold tool using a robot. After injection molding, the label becomes an integrated part of the final product.
- Assembly: We perform assembly tasks such as various types of threaded inserts. It can also involve different types of sub-assembly or packaging before delivery.
- Printing: We work with several methods, including pad printing, digital printing, and heat embossing. Printing can be done in-line or as a post-process.
- Ultrasonic Welding: The choice of thermoplastic, geometry, and energy director design are some of the factors that affect the quality of the welded result. A correctly executed weld provides a joint that is stronger than the surrounding material.
Yes, this can be done using different printing methods or if it is already part of the component's geometry.
Pad printing is a simple process for printing on plastic components. It is also often referred to as pad printing. It offers great flexibility in choosing colors. The printing can be done as part of the production line or as a post-processing step. Using a stencil and a silicone pad, the color/pattern is transferred to the component.
At its core, injection molding involves the transformation of plastic pellets into finished products through a controlled and repeatable manufacturing process. The pellets are heated until they reach their melting point, and then they are injected under high pressure into a carefully designed mold cavity. When the plastic cools and solidifies, it takes the shape of the cavity, resulting in a finished product.
- The choice of material affects the shrinkage compensation required by the tool.
- The choice of material can affect the dimensional accuracy of the component.
- The design of the component can affect dimensional accuracy and the risk of sink marks.
- If we get involved early in the project, we can assist with product feedback to make the component more suitable for quality-assured manufacturing.
- The number of components to be produced affects the tooling solution. Is it prototypes, low volumes, or high volume?
