The design and manufacture of custom molded plastic parts can seem simple at first, but there are many details that must be taken into consideration depending on how the part will be used. For example, there are mechanical properties like:

Vacuum casting is an excellent alternative to injection moulding for quantities between 10 to 50. It shares many similarities in terms of technique and final outcome—from function to aesthetics—but without the high upfront costs or long lead times of injection moulding. This method offers a wide range of resins that can mimic ‘production-grade’ materials, from soft elastomers with varying shore hardness to hard plastics like ABS. For these reasons, urethane casting is often used for end-use small production runs of a product that will eventually be injection moulded.

As a leading small plastic parts manufacturer, we work with engineering grade plastics to create custom molded plastic parts that match the requirements for a part with properties like: chemical resistance, flexural strength, durometer, and yield strength to name a few. There are so many material options, and we can help you make the right choice for your program.

3D printing is a very affordable and quick alternative to plastic injection moulding for early-stage prototypes and short production runs, especially for smaller-sized parts. 3D printing technologies like industrial stereolithography (SLA) requires no tooling costs and is able to give a nice surface finish that resembles injection moulded parts. Although it may lack in some aspects of strength or properties, 3D printing has come a long way and is increasingly being used in low-volume end-use applications.

“We received the charger base and I want you all to know it looks FANTASTIC! Thank you for getting us this one for the BOD meeting.”

3D Printed Moulds3D printed moulds are the latest trending technique in mould making. They offer a cost-effective and rapid alternative to traditional injection moulding, suitable for 30 to 100 units or more (depending on the material being injection moulded). The key limitations of 3D printed moulds are accuracy constraints, as well as lower durability and heat resistance compared to metal moulds. Advantages:Cost-effective for small batches of parts.Less commitment and facilitate quicker iterations. Limitations:Size and accuracy constraints.Temperature and pressure limitations of plastic moulds.  Thermoforming ManufacturingThermoforming is a good alternative to injection moulding for ‘relatively’ simple plastic parts like packing containers, vehicle door panels, and dashboards in low-to-mid volumes. It involves creating a simple single-sided mould of the product. A thin sheet of plastic is then heated and formed using vacuum, pressure, or mechanical force. Advantages:Cost effective for low-to-mid volumes.Efficient for simple plastic parts. Limitations:Achieving consistent wall thickness can be challenging.Not suitable for highly complex parts.  CNC MachiningCNC machining is a highly reliable process that can be a good alternative to injection moulding, especially for creating more rigid and durable parts in low-to-mid volume quantities with high precision and accuracy. In fact, the precision moulds used in the injection moulding process are made via CNC machining. Advantages:Excellent for high precision, high tolerance parts.Fast turnaround time for low-volume production parts. Limitations:Not compatible with rubber, silicone and other soft plastics.Can be time-consuming and expensive for very complex geometries.  Source Custom Plastic Parts With HLH RapidAt HLH Rapid, we help mechanical engineers, industrial designers, and R&D teams bring their products to market faster through our rapid tooling and injection moulding, CNC machining, 3D printing, and a range of other in-house manufacturing services. Whether you need a single part or mid-to-high production volumes, we can cater to your needs.Ready to start your next project? Submit your 3D CAD to our contact form here to get a quote or discuss your project requirements.

It is then injected under enormous pressure into a steel or aluminum mold, cooled until it hardens, and ejected. With small part injection molding, we are able to manufacture complex, small shapes in a cost-effective, repeatable process.

CNC machining is a highly reliable process that can be a good alternative to injection moulding, especially for creating more rigid and durable parts in low-to-mid volume quantities with high precision and accuracy. In fact, the precision moulds used in the injection moulding process are made via CNC machining.

Plastic injection moulding is the most common way to manufacture all types of plastic parts and is particularly effective for large orders. However, the tooling process can be expensive and require longer lead times than other methods. For small batches and prototypes, there are quicker and more affordable ways to produce plastic parts.In this article, we explore the top alternatives to injection moulding that allow cost-effective manufacturing of low-volume parts (in the tens or hundreds), enabling you to test the market, receive feedback from users, present your product to investors, run promotions, and more. Vacuum Casting(Also known as: Urethane Casting / Polyurethane Casting / Silicone Moulding / Soft Tooling)Vacuum casting is an excellent alternative to injection moulding for quantities between 10 to 50. It shares many similarities in terms of technique and final outcome—from function to aesthetics—but without the high upfront costs or long lead times of injection moulding. This method offers a wide range of resins that can mimic ‘production-grade’ materials, from soft elastomers with varying shore hardness to hard plastics like ABS. For these reasons, urethane casting is often used for end-use small production runs of a product that will eventually be injection moulded. Advantages:Lower upfront cost and faster lead times for short production runs.Wide selection of polyurethane materials and good surface finish. Limitations:Silicone tools typically only last 25 shots before the tool will need to be replaced.Higher unit price than injection moulding.  3D Printing3D printing is a very affordable and quick alternative to plastic injection moulding for early-stage prototypes and short production runs, especially for smaller-sized parts. 3D printing technologies like industrial stereolithography (SLA) requires no tooling costs and is able to give a nice surface finish that resembles injection moulded parts. Although it may lack in some aspects of strength or properties, 3D printing has come a long way and is increasingly being used in low-volume end-use applications. Advantages:Fast and cost-effective for very small production runs.Can print parts with highly complex geometries. Limitations:Material and size constraints.May lack in some aspects of strength or quality.

Plastic injection moulding is the most common way to manufacture all types of plastic parts and is particularly effective for large orders. However, the tooling process can be expensive and require longer lead times than other methods. For small batches and prototypes, there are quicker and more affordable ways to produce plastic parts.

AIM Processing specializes in small part plastic injection molding. We define "small plastic parts" as roughly the size of your fingernail to the size of your hand. Injection molding is a process in which plastic resin, in pellet form, is heated and sheared until it reaches a viscous state.

Then there are factors like the manufacturability of gate locations, draft, and ejector pins. It's enough to make your head spin.

3D printed moulds are the latest trending technique in mould making. They offer a cost-effective and rapid alternative to traditional injection moulding, suitable for 30 to 100 units or more (depending on the material being injection moulded). The key limitations of 3D printed moulds are accuracy constraints, as well as lower durability and heat resistance compared to metal moulds.

At HLH Rapid, we help mechanical engineers, industrial designers, and R&D teams bring their products to market faster through our rapid tooling and injection moulding, CNC machining, 3D printing, and a range of other in-house manufacturing services. Whether you need a single part or mid-to-high production volumes, we can cater to your needs.

We are thrilled to announce that AIM Processing will be exhibiting at the 2024 Long Beach Manufacturing Trade Show in September! This premier event ...

Discover AIM Processing's customer small part injection molding services, designed to deliver precise, high-quality components for industries requiring intricate and complex plastic parts.

Ready to start your next project? Submit your 3D CAD to our contact form here to get a quote or discuss your project requirements.

Thermoforming is a good alternative to injection moulding for ‘relatively’ simple plastic parts like packing containers, vehicle door panels, and dashboards in low-to-mid volumes. It involves creating a simple single-sided mould of the product. A thin sheet of plastic is then heated and formed using vacuum, pressure, or mechanical force.

AIM Processing has acquired Technical Molded Products, solidifying its position as a leading injection molder in the western United States. Key ...

In this article, we explore the top alternatives to injection moulding that allow cost-effective manufacturing of low-volume parts (in the tens or hundreds), enabling you to test the market, receive feedback from users, present your product to investors, run promotions, and more.

Maintaining proper wall thickness is one of the most important aspects of designing custom injection molded parts. Overly thick walls not only waste ...