Soft Plastic Lure Injection Machine? Top 99 Best Answers

3D printing with flexible plastics

The most common materials used to print soft plastic parts are TPU (Thermoplastic Polyurethane) and TPE (Thermoplastic Elastomer). TPU is a straight chain elastomer with good chemical, wear and abrasion resistance. Due to the presence of hard and soft segments in its chemical composition, it can be combined in different proportions to adapt the hardness of the TPU to the mechanical requirements of the specific application. TPE is a very elastic polyurethane-based material, but additives are added to increase its ability to deform and recover its shape without breaking. Unlike the glossy finish of TPU, it has a matte finish.

Shawn Rutledge, an inventor of unique fishing lures, has found success and scored some big fish with his lures. Having been an avid angler all his life, his passion for making fishing lures led him to Smooth-On’s Technical Helpline in search of materials. After considering various options from his product line, Shawn settled on Feather Lite™ lightweight casting resin and Smooth-Cast™ 320 casting resin. He found that a combination of Feather Lite resin and Smooth-Cast 320 resin den provided the perfect buoyancy he needed for his lures. The resins were very easy to use and paint which made his design possibilities limitless.

Shawn started his own company, designed and manufactured the lures in his backyard, and worked with Mold Max™ Silicone, Feather Lite Light Resin and Smooth-Cast 320 Cast Resin. Since then he has developed a whole range of lures and gained almost a cult following.

Custom Fishing Lure designer Shawn Rutledge showcases part of his collection made with Feater Lite® resin.

Feather Lite® is used to make a variety of fishing lures.

Feather Lite® is easy to edit and finish.

Feather Lite® can be easily painted or lacquered.

Feather Lite® resin is poured into a Mold Max® silicone mold.

Mold Max® silicone and Feather Lite® resin are a perfect, easy-to-use combination for fishing lure making.

The short answer: Plastic injection molds cost anywhere from $100 for a low-volume, 3D-printed injection mold to over $100,000 for a complex multi-cavity steel mold for high-volume production, which is generally the most significant fixed start-up cost in the injection molded part. However, because this cost is spread across hundreds or thousands of parts, injection molding is an ideal method for low-cost, mass-production of plastic parts. In this guide, we provide an in-depth breakdown of the various factors that make up the total cost of injection molding.

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Introduction: How Much Does Injection Molding Cost?

Injection molding is one of the leading processes for the production of plastics. It is often used for mass production of identical parts with tight tolerances. It is a low cost and highly repeatable technology that delivers high quality parts for high volume production. It’s a fast, intense process that requires high heat and pressure to inject molten material into a mold. The material melted depends on the scope of the fabrication project. The most popular materials are various thermoplastics such as ABS, PS, PE, PC, PP or TPU, but metals and ceramics can also be injection molded. The mold consists of a cavity that holds the injected molten material and is engineered to accurately reflect the final features of a part. The main cost drivers in injection molding are usually the tooling costs, also known as tooling costs. The cost of designing and building a mold depends on the volume of production required, the complexity of the part design, the mold material, and the process used to make the mold. Simple, low-volume 3D-printed shapes can cost as little as $100, while the cost of designing and manufacturing complex shapes for mass production can reach the $100,000 mark. Despite the significant fixed start-up costs, the injection molding process has low variable costs due to the low-cost thermoplastic materials, short cycle times and labor input is increasingly reduced due to automation and economies of scale. This means that the variable production costs are low and the process becomes more efficient and the cost per part decreases with higher volumes as the costs are spread over hundreds or thousands of parts.

In this video we’ve teamed up with injection molding service provider Multiplus to walk you through the steps of the injection molding process using 3D printed molds.

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Types of costs in injection molding

Understanding the different types of costs associated with injection molding requires a thorough analysis of the process.

equipment costs

Specialty machines are used for injection molding, which can range from smaller desktop injection molding machines that companies can use in-house to large industrial injection molding machines that are mainly operated by service providers, contract manufacturers and large manufacturers. Injection molding small batches of parts is most cost effective with smaller desktop injection molding machines and 3D printed molds. If you are new to injection molding and want to try it out with limited investment, using a manual benchtop injection molding machine like the Holipress or the Galomb Model-B100 could be a good option. Automated small series injection molding machines such as the Micromolder table machine or the Babyplast 10/12 hydraulic machine are good alternatives for the small series production of small parts. Large industrial injection molding machines can cost anywhere from $50,000 to over $200,000. These machines are also subject to stricter plant requirements and require qualified personnel for operation, maintenance and supervision. For this reason, most companies outsource mass production to service providers and subcontractors unless injection molding is a core competency, with equipment costs included in service costs.

mold costs (tool costs)

As mentioned at the beginning, tool costs or tooling costs are usually the main cost driver in injection molding. Molds for injection molding are generally made using three methods: CNC Machining: CNC machines are the most commonly used tools to produce aluminum and stainless steel molds with high precision. CNC machining removes material through a rotating tool and a fixed part. Machining can produce shapes where the cavity design is very complex, but it may require multiple tool changes that can slow down the process, meaning costs increase with complexity. CNC machines are industrial tools that require skilled labor and dedicated space, which means many companies outsource mold making to service providers.

Electro Discharge Machining (EDM): The EDM process is commonly used to create highly complex mold designs that cannot be readily reproduced using standard machining methods. EDM involves using a workpiece and a tool electrode to create the desired mold shape. The tool electrode and work electrode are separated by a dielectric fluid and are subjected to voltages that cause repetitive current discharges. The discharges are responsible for shaping the workpiece electrode into its final shape. EDM is highly accurate and generally does not require additional post-processing. Similar to CNC machining, EDM is an industrial process that many companies outsource to machine shops.

3D Printing: 3D printing is a powerful solution to create injection molds quickly and inexpensively. It requires very limited equipment, saving CNC time and skilled operators for other high-value tasks in the meantime. Manufacturers can take advantage of the speed and flexibility of in-house 3D printing to create molds that can be used on both desktop and industrial molding machines. In addition, product development benefits from the ability to iterate on the design and test the end-use material before investing in hard tooling for mass production. Stereolithography (SLA) 3D printing technology is a good choice for injection molding. It is characterized by a smooth surface finish and a high level of precision, which transfers the shape to the final part and which also facilitates demoulding. 3D prints made by stereolithography are chemically bonded to be fully dense and isotropic. Desktop SLA printers like those offered by Formlabs start under $5,000 and integrate seamlessly into any injection molding workflow because they are easy to implement, operate, and maintain.

3D printed molds can produce more than 100 parts inexpensively and in a matter of days.

The development of more complex shapes requires technical know-how. As a result, companies often outsource certain aspects of the injection molding process, e.g. B. the design and manufacture of the mold. For companies that have the equipment and tooling to do injection molding, the decision to make molds in-house could be the most cost-effective option if the technical know-how is also there. When the tooling needed for injection molding is not readily available, outsourcing reduces the costs associated with developing a mold. Simple, low-volume 3D-printed shapes can be made on an SLA 3D printer for as little as $100. An aluminum mold for a medium production run of about 1,000 to 5,000 units falls in the $2,000 to $5,000 range. For molds with more complex geometries and prepared for larger production runs of around 10,000+ units, the cost of the mold can range from $5,000 to $100,000.

Injected Material Cost

A variety of plastics can be used for injection molding, depending on the end part requirements, including ABS, PS, PE, PC, PP or TPU. The cost of purchasing materials for molds differs depending on the material chosen. Thermoplastic pellets cost approximately $1 to $5 per kg. Material cost is defined by the design of a model, the material chosen, and the amount of material used to perform the injection molding process.

labor or service costs

The equipment associated with injection molding is generally self-regulating and relies on automation to get the job done. CNC machines, EDM machines, and 3D printers rely on CAD design specifications to produce a mold. The injection molding machine also relies on automation to inject materials into the mold, and industrial IM machines often autonomously cool and eject the finished product. Labor costs include: Setup/Configuration Costs: Setup labor focuses on the time it takes to configure the equipment used to produce the mold and finished product.

Repair Costs: Repair and maintenance tasks involve replacing defective parts and using tools to perform the maintenance process.

Monitoring Costs: Despite the reliance on automation, line operators are expected to monitor the progress of the injection molding process. Operator wages incurred during the process are added to the total cost of injection molding. In the case of in-house production, these costs are included in the labor costs. When a company outsources injection molding, the service provider’s labor and mark-up are added to the service cost.

Webinar injection molded parts in <24 hours? Low Volume Injection Molding 101 In this webinar we will show you how to use 3D printed Stereolithography (SLA) shapes in injection molding to reduce costs, reduce lead times and bring better products to market. Watch the webinar now Cost overview injection molding The table below highlights the costs associated with injection molding a hypothetical plastic item, e.g. B. a small housing of an electronic device, which makes the cost dynamics of injection molding easier to understand: Small batch production Medium batch production Large batch production Production volume 100 5,000 100,000 Method In-house mold making and shaping Outsourced mold making and shaping Outsourced mold making and shaping Shape 3D printed polymer Machined aluminum Machined steel Lead time to finished parts 1 -3 days 3-4 weeks 4-8 weeks Equipment required 3D -Printer, Desktop injection molding machine* - - Tooling cost $100 $3,000 $20,000 Material cost $0.5/part $0.5/part $0.5/part Labor cost or outsourcing cost $2.5/part $1.5 / part $1 / part Total production cost $400 $13,000 $170,000 Cost per part $4 $2.6 $1.7 * Equipment costs are not included in the production costs in this example as the cost of these tools can be spread across multiple projects. By purchasing a desktop injection molding machine and an SLA 3D printer, companies can start injection molding for less than $10,000. The three scenarios in the table show the methods and tool types that result in the lowest unit cost depending on the production volume. In general, injection molding is most efficient at higher volumes because the cost is then spread over thousands of parts. However, while the cost per part for low volume injection molding is slightly higher, it is still significantly more affordable for low volume production than other manufacturing processes. Mid-volume production is most efficient with machined aluminum molds, which are less expensive than traditional steel molds but are durable enough to last a few thousand shots, depending on factors such as material and design. In most cases, low-volume injection molding only makes sense with 3D-printed molds – in our example, if we were to use an aluminum mold to produce 100 parts, the cost would be $30 per part, while a traditional steel mold would the case would mean $200 for each part. Variables affecting injection molding costs The tooling cost for injection molding is very high and depends on a number of parameters and the complexity of the design. Molds for injection molding are typically CNC machined from aluminum or tool steel, EDM to form a workpiece, or 3D printed. The machined or printed part is then finished to meet the desired standard. The finished mold consists of features such as the surface geometries required for a part, a gating system to guide the flow of injected materials, and cooling channels to ensure the mold cools quickly. It is important to note that much of the injection molding process is dedicated to cooling. The faster a mold cools, the faster the injected material solidifies and the faster the production cycle can be repeated. Cooling channels therefore play an important role in large-scale production and should be taken into account when designing the tool. For small series production with 3D printed molds, manual cooling with compressed air is an option. A 3D printed injection molded core assembled with a metal mold shell. Other variables that affect the injection molding process and are directly related to injection molding costs are: Part size: The larger the object or part to be injected, the larger the mold to accommodate the part. Larger parts typically require more injected materials to complete production cycles. Larger mold designs are usually more expensive than producing the same design but with smaller dimensions. Part Design: Complex part designs with intricate geometries require complex shapes to complete the project. Shape designs usually have 2 sides: Sides A and B. Side A, also known as the cosmetic side, is usually the side seen by the user. Side A should be smooth and aesthetically pleasing. Side B contains the hidden structures that support the use of the part. Side B's structure may contain ribs, protrusions, etc., and its surface is usually much rougher than Side A's. Molds with complex Side A and Side B designs are generally more expensive to manufacture compared to simpler ones To form. Complex undercut designs may also require sliding side moves and cores, increasing the cost of the mold. Production volume: The number of pieces to be produced in injection molding determines the production technology and the quality of the material used in the manufacture of the mould. Low volume projects may require 3D printed or low quality machined aluminum molds, while large production volumes require high quality steel molds or even multiple molds to handle the process without wear and tear affecting the quality of the items produced. This affects the cost of the mold, but of course the increased cost of high volume molds is spread across more parts, usually resulting in a lower cost per part. Partial Volume and Cavities: Partial volume refers to the cavity size of a mold. The more cavities or cavity volume a tool requires, the longer the pressing time. An extended pressing time slows down the production process, which leads to increased costs. White Paper SLS 3D Printing vs. Injection Molding: When to Replace Molded Parts with 3D Printing? This white paper shows the cost dynamics for real-world use cases and provides guidelines for using SLS 3D printing, injection molding, or both. Download the white paper Injection molding cost calculator Online injection molding estimators or quotes from injection molding service providers can provide benchmarks and help you estimate the cost of injection molding specific parts. Injection molding cost calculator options to aid in the calculation process include: CustomPart ICOMold 3D hubs The Protolabs Mold Cost Comparison Chart serves a similar purpose. Molding service providers use cost comparison charts to give prospects a rough idea of ​​the process. Injection molding cost reduction The cost of the mold is largely determined by the complexity and time required to manufacture it. We recommend adhering to Design for Manufacturing principles to reduce part costs when injection molding. The cost of producing the mold can be reduced by using the following design guidelines: Before undertaking an injection molding project, evaluate the CAD model to determine its feasibility. Eliminate potential bottlenecks such as steep angles, undercuts, and other complex geometries. Evaluate the design of the model to eliminate unnecessary features. This reduces the size of the mold and the material used to develop the model. Apply a core cavity approach that simplifies the design of side B of a mold. The core cavity approach involves countersinking the wall cavities into the mold base, reducing the need to mold steep draft angles while improving surface finish. Embrace the use of self-fitting parts to reduce the need to create multiple molds when a universal mold can be used to achieve similar results. Start with rapid injection molding

A small and simple single cavity plastic injection mold typically costs between $1,000 and $5,000. Very large or complex shapes can cost up to $80,000 or more. On average, a typical mold making a relatively simple part small enough to hold in your hands costs about $12,000.

But, at least to some extent, asking the cost of plastic injection molding is like asking, “How much does a car cost?” Do you want your mold to be a Pinto or a Porsche? And don’t forget that the price of a mold is just the start. Later, to determine the total cost of plastic injection molding for any project, you also need to consider raw material, operation, and repair costs.

The cost of making a plastic injection mold

The factors that determine the cost of your mold are a combination of part size, complexity, material, and expected quantities. For example, if you want 1,000 washers per year, we recommend a single cavity mold, i. H. one washer is produced per machine cycle. In this case, the mold would likely cost $1,000 to $2,000.

However, needing 100,000 Xbox controllers every month is a different story. For this requirement, we would recommend building a hardened 12-cavity “family mold” that would make four faces, four backs, and four button trees in each cycle. Of course, this type of mold comes at a cost. You’d better invest $60-80k or more!

These examples are extreme, but they illustrate the range of costs to be expected. Your specific part will most likely fall somewhere in between. At Rex Plastics, our molds average around $12,000.

Is injection molding expensive?

The start-up costs for a large run can be high, but the price of the project only gets better as you keep producing. When you consider the price per unit, plastic injection molding is one of the cheapest and most cost effective forms of manufacturing. When it comes to injection molding, the more units you make with your mold, the cheaper the unit price will be.

Plastic Injection Molding Price Guide

As a full service plastic injection molding company, manufacturing molds from conception to completion, prices can vary significantly for each job we complete.

However, we know that injection molding cost estimates are critical to any successful project.

With that in mind, we’ve put together the pricing guide below to help you budget for your mold. The injection molding cost examples are categorized by type (rapid prototyping, insert tooling, high-production tooling) and difficulty level (basic, intermediate, advanced).

Material costs for injection molding

Material selection is another consideration when determining the cost of plastic injection molds. Any plastic product made from fiberglass reinforced material, for example, wears out of most common shapes. Only a mold made of hardened tool steel can withstand injection molding with glass fiber reinforced material.

Plan your next project

If you have set a target price for your parts, let your mold maker know. You can design the mold accordingly and plan the right number of cavities to achieve that price. The more cavities (or parts per cycle) made, the cheaper the parts, which also allows for higher output.

While you don’t need to know every detail about the types of shapes available, it’s always a good idea to be prepared. Providing the basics to your mold maker will help them build the best tool for your project. We encourage you to find a mold maker that also has production capabilities. The company running the production will not want to build an inappropriate mold because they know they have to use it.

And if you’re thinking of outsourcing your mold making operation abroad, consider all of the factors to bring the mold to optimal production standards outlined in this article by the American Mold Builders Association. You may be surprised to learn the true cost of offshoring!

Whatever your project requires, Rex Plastics can help you decide whether you need a Ferrari or a Fiat.

If you want to add special physical properties to the resin you use, or just want to defray the expense of using pure plastic resin, you can add additives. Commonly used materials such as plasticizers and mineral fillers are some of the cheapest that can be used, while products such as lubricants and heat stabilizers can cost more than the polymer itself. There is a wide range of additives that impart a variety of properties including glass fibre, ceramic fillers, pigments, UV stabilizers, plasticizers and antioxidants. These materials can increase strength, impact resistance, durability, elasticity and fatigue limit.

In addition to the physical properties, the color of the component can also be influenced, which is one of the most popular applications for additives. These vendors also sometimes partner with thermoplastic manufacturers to offer customers better deals.

Tooling costs for injection molding

Injection molding tools for a medium order (about 1000-2000 small parts) can cost up to $10,000. For more complex geometries and large orders, the cost can be as high as $100,000.

Tooling costs depend on how complex or large your parts will be. In other words, if your part is complex (e.g. if it has intricate geometry or dense walls), the manufacturer may need to use a special (i.e. more expensive) machine to complete your order.

Injection mold tooling costs increase exponentially when dealing with a large custom part. From the operator’s point of view, it is preferable to use small (desktop) injection molding machines (and even 3D printers) to fulfill low-volume orders.

Large, industrial plastic injection molding machines can cost over $200,000 with additional costs associated with training, maintenance, supervision and even industry regulations for skilled workers. These machine types are reserved for large series orders.

injection molded parts

Injection molded part costs vary based on mold maintenance, time to mold a part, and factors related to the plastic. These include part rate, estimated scrap (typically 3-5%), plastic weight, and sometimes a tool maintenance fee that covers the cost of mold tooling warranties. The offer price should also include any set-up costs for the moulds.

1. Injection molding cycle time

Cycle time in injection molding accounts for approximately 60% of the final cost of the part. The part rate depends partly on cycle time and partly on cavitation, which is discussed in the next section. In general, manufacturers have set hourly rates that they charge for their machines.

The molding cycle can be divided into two parts:

injection time. This represents the time it takes for the polymer (material) to be injected into the mold. It is usually a few seconds and depends on the power and shot size of the machine.

cooling time. This corresponds to approximately 80% of the total cycle time. This greatly affects the quality of the final part as it is the time it takes for the material to cool and shrink.

The total cycle time can be estimated as follows:

In this equation, α is the coefficient of thermal conductivity and h max is the maximum wall thickness in millimeters. While the former is a material-specific constant, the latter is a design choice or requirement. Depending on the complexity of the part, the cycle time can be up to two minutes.

As a manufacturer it is preferable to keep the cycle time as low as possible as this results in the production of more parts in a given time.

2. Mold cavitation

Mold cavitation cost, another factor in part price, increases with the number of cavities. Cavitation is the number of identical cavities that produce parts per mold. The injection mold itself can cost thousands of dollars.

Mold cavitation is related to part size and design. If your part is relatively simple, single-cavity molds are usually cheaper. However, if the geometry of the part allows, it is preferable to opt for multi-cavity molds to speed up the production process (thereby making production cheaper over time). However, larger parts may not allow this.

You can either buy a ready-made injection mold or have one made. Using pre-made molds is a common practice and is the more cost-effective option, especially in the electronics industry due to the widespread use of standardization. You can also have one made for you, which is better for unique designs.

Another consideration is that with custom injection molding tools, the geometry must be compatible with the machine used by the manufacturer. This limitation can affect your project (and possibly the design). Therefore, it is best to make sure that the company you are interested in can do the job.

3. Plastic weight

The plastic weight cost includes both the plastic molded into parts and the cured plastic remaining in the mold. You also have to cover the cost of the plastic weight, not just for the parts, but also for the sprue, sprue, and sprue (the sprue and sprue are channels through which molten plastic flows to get into the mold while the sprue prevents plastic from flowing out when inside). For example, if you end up with 4 pounds of parts and 1 pound of leftover plastic to set in the sprue and sprue, you will pay for 5 pounds.

Fixed scrap rates also factor into the final cost of injection molding. These serve to free the plastic injection molding machines from previous plastics from cylinders and screws and to reload them with your plastic.

4. Cost of setting up the injection molding process

Tooling setup costs include optimizing the process as well as physically setting up the materials and machinery to manufacture your parts. These are part of the final price per part. The process is streamlined, and there may be some lead time that goes into the preparations that most companies charge as their own flat fee. This can include processes like drying the resin, hanging the molds, arranging water pipes, external issues, and any type of sensors in the mold. It can also include any type of special cooling required or a special gating scheme that acts as a hot manifold system (which keeps the channels hot enough to keep the plastic inside them liquid).