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Prototype Injection Molding

Prototype Injection Molding

Prototype and low volume injection molding

Precise plastic material as final design

Molding quantities from 100 pieces

Cost much lower than production molds

Fast delivery within a few days

Why choose our rapid tooling?

Top Quality

From prototype molds, we can produce high quality molds that are very close to mass production or 100% match the final production level.

Better Price

Our experienced engineers can find the best solution to save money and maintain high quality molds. For example, better rapid mold design concepts, mold material selection.

Faster delivery

With our in-house facilities, large inventory of mold components, and our manufacturing network, we can manage to have your rapid processing and final molding done in a matter of days

Quick mold material

Aluminum mold tooling

Ideal for prototyping, aluminum molds offer a cost-effective way to produce molded parts. Because it is easy to cut, aluminum molds can reduce processing costs by 15-25% and reduce cycle times by up to 40% compared to other mold materials. This means faster turnaround for our customers.

Aluminum dissipates heat evenly, which provides dimensional stability in the mold. This significantly reduces distortion and creates less waste in the production process. It is important to note that aluminum is not as strong as steel, so it has a shorter life cycle and is less useful in high-volume processes.

Steel Tooling

Steel is a strong, robust, quality tooling material, but it is not suitable for all applications. Steel tooling has a longer life cycle than aluminum tooling, making it ideal for high volume production. Steel can also be used to produce engineering grade plastic molds that are resistant to wear and corrosion.

While it offers several advantages, steel is a more expensive tooling material than aluminum and requires more turnaround time to produce molds and prototypes.


Prototype Injection Molding

Prototype injection materials

In general, plastics that can be used to produce injection molding can also be molded by hand molding. The following are the most common molded plastics. If a material is not listed, please contact our team for more information.

Thermoplastics

ABS ABS/PC Acetal Acetal copolymer Acetal homopolymer/Delrin Polyurethane resin High density polyethylene Liquid crystal display Low density polyethylene Linear low density polyethylene Nylon PBT Polycarbonate/PBT Peep Pets PETG PMMA (Acrylic, Plexiglas) Polycarbonate Polypropylene PPA Personal protective equipment/Personal protective equipment Polystyrene Power supply Thermoplastic polyurethane

Thermoset plastic

Standard silicone (30, 40, 50, 60 and 70 durometer) Medical grade silicone Optical grade silicone Fluorosilicone rubber (fuel and oil resistant)

Benefits of Rapid Prototyping Plastic Parts

Rapid prototyping injection molding is a preferred method that not only helps engineers and designers confirm part quality, but also provides real parts that can be tested in the marketplace before the design is considered finalized. In addition to design verification and structural validation, you can use rapid prototype injection molding to help complete the mold design for long-term production runs. Other benefits of making prototype plastic parts before full-scale production begins include

Faster, more reliable product launches: Many products fail for a variety of reasons, including cost and price calculation errors, lack of market testing, and worst of all - product failure. Rapid prototyping and market testing can reduce these challenges before a product is released.

Better product functionality and appearance: When aesthetic judgments are made about products based on engineering drawings and visualizations, they often fail to impress in real-world production scenarios. You can also test prototype samples on site for functionality and aesthetics.

A more efficient design process: Prototypes can actually help shorten the overall engineering and design review phase of a new product. And, when you have prototype plastic parts on hand, you can easily prove its market viability to stakeholders.

Reduce tooling costs: When manufacturers don't make prototypes, they often have to rework their production tooling. If you choose rapid prototype injection molding, you'll identify and solve any challenges before making expensive production molds.

What is injection molding?

Plastic injection molding is the process of melting plastic pellets (thermoset/thermoplastic polymers) and once they are sufficiently ductile, they are injected into the mold cavity under pressure, filled and cured to produce the final product.

How does injection molding work?

Kesu's thermoplastic injection molding process is a standard process involving aluminum molds. Aluminum is much more efficient at transferring heat than steel, so no cooling channels are required - meaning the cooling time we save can be used to monitor filling pressures, cosmetic issues and produce quality parts. 


Resin pellets are loaded into a barrel and eventually melted, compressed and injected into the mold's runner system. The hot resin is injected into the mold cavity through a gate and the part is molded. An ejector pin helps remove the part from the mold and the part drops into the loading bin. After the run is complete, the part (or initial sample run) is boxed and shipped shortly thereafter. Request your free design cube, which shows surface finish and thickness finish.  


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