Injection Molding Frequently Asked Questions

Getting Started

What critical questions should I ask before starting an injection molded project?

We’ve narrowed it down to 10 critical questions you should ask before beginning any injection molding project. Armed with these questions, you’ll be ready to start your next project on the right track. No wasted time, no surprises. Read More

What custom injection molding services are available from Ferriot?

We offer a variety of custom injection mold design and services, including supply-line development, supply-line management, process qualification, product testing, drop shipping, and final assembly. Read More

How do I request a quote for an injection molding project?

Simply fill out the form on the following page Request a Quote

What should I consider if I want to move my molds to another injection molder?

The ideal solution is one in which the existing supplier, new supplier and customer are able to openly communicate while maintaining all customer deliverables in the process. However, when this is not possible, having a supplier that has experience with this type of transaction is extremely invaluable.Read More

How do I know what injection molding method I will need?

Complete our simple worksheet to find out. Read More

Custom Mold Design

What are the biggest benefits of plastic injection molding?

Injection molding for manufacturing is one of the most cost-effective ways to go. Other considerations include plastic part durability and longevity, customer and client satisfaction, part tolerances and overall labor costs. Read More

What are the questions to answer before starting with a custom mold design?

Take the time to answer the following questions before you attempt to design molds for injection molding; How will the part be used? How will this component integrate with other parts in the final assembly? What kinds of loads and pressure will it be subjected to?Read More

What aspects of custom mold design need to be considered before starting?

A part’s features must be reviewed carefully in terms of how the resin material enters and fills the mold cavity, as well as how the material cools while in the mold. An experienced tool design engineer understands how to control mold temperature and cooling rate process optimization. This critical step will help to optimize cycle times, reduce stress in the part and prevent various physical and cosmetic defects. The result is a stronger part that is easier to manufacture.Read More

What are the mold gate types and mold gate design options?

The gate’s design, location, and type have important effects on the final part, including packing, gate vestige, dimensions, warping, and overall cosmetic appearance. Two types of gates are used in injection molding: manually trimmed and automatically trimmed.Read More

When should EMI/RFI shielding be used in custom molded part design?

Virtually everything with an electrical signal causes some level of EMI or RFI interference, proper shielding for injection molded component parts is necessary to meet regulatory requirements as well as ensure continued, reliable performance.Read More

How can I manage or even cut costs in my injection molding part design?

With injection molding, a variety of factors affect a part’s final cost, including part design, production time, the temperature and pressure used, and the type of plastic resin chosen. However, there are bigger issues to consider long before your part is in the mold. Following some industry best practices will go a long way toward minimizing your part costs without compromising your design goals.Read More

Injection Molding Processes

What is gas assist injection molding?

Gas assist injection molding (GAIM) is an enhanced injection molding process often applied for complex parts, large parts and parts requiring an attractive, cosmetic finish.Read More

What is insert molding and how is it used?

Insert molding is the process of placing of an object (insert) into an injection mold and then encasing some portion of it in plastic.Read More

What are the differences between structural foam molding and injection molding?

Injection molding begins with melted thermoplastic being injected into a mold, and a packing stage where pressure is built and the plastic is formed into the shape of the mold. In structural foam molding, the injection stage is basically the same, but the packing stage is augmented by a chemical blowing agent mixed with the material.Read More

What is structural foam injection molding?

Structural foam molding is an option available to manufacturers who are looking for a way to create stronger, more rigid plastic parts. It is also a method used to reduce potential part weight for larger parts.Read More

What are the advantages of using structural foam molded parts?

Structural foam parts have much higher strength-to-weight and strength-to-stiffness ratios than injection molded parts. They are also much more impact resistant due to the microcellular structure.Read More

What is over molding?

Over molding is process that adds a softer touch to molded parts while also improving grip on hand controls and providing water resistance and sound absorption.Read More

Painting & Decorating

What painting and decorating services does Ferriot offer?

Our services include pad printing, hot stamping, digital printing, and product painting and plating. We deliver both finished products and subassemblies.Read More

How can I use pad printing to add company branding to injection molded parts?

When it comes to adding your brand or other information to your injection molded parts, pad printing offers some very valuable advantages.Read More

What are the advantages of painting plastic molded parts?

Painting after the injection molding process is a good solution when requirements cannot be met with just a custom colored resin. This can be due to several factors that include appearance, UV protection and improved functionality.Read More

Quality & Efficiency

How are mold flow analysis (MFA) and tool design used to improve molded part quality?

Mold flow analysis (MFA) and tool design are both very important aspects in the injection molding part design and troubleshooting process. They help assure that a new mold tool design will yield quality parts that meet or exceed expectations.Read More

What are the typical problems that MFA helps to find and solve?

There are numerous detailed reports within the results of the MFA, not only the answer to “will it fill properly?”, but it will identify areas that may not hold up under stress, where the hot spots or thick areas are in the mold.Read More

How is Stereo Lithography (STL) used with PolyWorks Inspector as part of TQM?

STL allows for smoothing and filling in of areas not scanned, allowing for more precise documentation of product qualityRead More

How are COBOTs used to make plastic molded parts manufacturing more efficient?

Cobots can handle all the repetitive and tedious elements of manufacturing, leaving operators open for more complex tasks and part analysis.Read More

Resin Selection

What do I need to know to make smart injection molding resin selections?

It’s essential to take some time to learn about the characteristics of thermoplastic resins. There are many different types and grades available.Read More

Why is it important to consider using custom resins for injection molding?

With all the various features to consider when it comes to resins including ductility, rigidity, dimensional stability, temperature tolerance, chemical resistance and more, there are many variations and trade-offs.Read More

How does the polymers selection affect the custom mold design?

A resin’s flexibility, moldability, strength, and cost all have an impact on the choice of mold material.Read More

Engineering Services

What engineering services does Ferriot offer?

Product design assistance, custom mold design, custom mold manufacturing, resin selection, and total quality management.Read More

How does Ferriot provide product design assistance? What is included?

The entire custom molding process is a rigorous journey from design to production readiness. How you design a mold, build it and validate it determines the foundational strength of the entire manufacturing process.Read More

What is mold flow analysis (MFA)? Why use it?

Mold flow analysis is a process to determine if a new mold tool design will yield quality parts that meet or exceed expectations.Read More

Value-Added Service

What value-added services does Ferriot offer?

Contract manufacturing, painting and decorating, EMI / RFI shielding, inserting, ultrasonic welding, and heat staking.Read More

What contract manufacturing services does Ferriot provide?

Our expertise includes engineering, product design, injection molding, custom molding, sub- and finished assembly and the on-time delivery of components and finished products for major industry.Read More

What should designers know about ultrasonic welding?

It is important for designers to consider product requirements when parts are being designed for ultrasonic assembly. Joint design and resin selection decisions are impacted by these inputs.Read More

Why use ultrasonic welding services for plastics manufacturing?

Ultrasonic welding is faster, safer, and cheaper than other means of bringing plastic components together.Read More

What are the differences Between EMI and RFI shielding?

The specific difference has a lot to do with the frequency at which electrical distortions fall between. All RFI is EMI, but not all EMI is RFI.Read More

What is heat staking? When should it be used?

Heat staking is one of the many processes used in plastic assembly when at least one of the parts is made from thermoplastic. In most cases, heat staking is the preferred method for joining metal parts to plastics. It is also used to join two dissimilar plastic components.Read More

Understanding Our Injection Molding Equipment

What is the AICON smartScan Structured Blue Light Scanner? How is it used?

The AICON smartScan is a new state-of-the-art piece of metrology equipment that helps us to accelerate the injection molded part development process. It’s a blue-light scanner, that works in conjunction with PolyWorks inspection software.Read More

How are COBOTs used to make plastic molded parts manufacturing more efficient?

Manufacturers looking to add cobots to their production lines can expect measurably better parts, sometimes in half the time.Read More

What are the capabilities of the Negri Bossi BIPOWER injection molding press?

The new press will have an integrated Columbia industrial PC and a variable delivery pump hydraulic system that allows for precise process control and high power efficiency. The support team at Negri Bossi will be able to monitor its operation remotely via the Internet at any time so they can perform diagnostics, troubleshooting, and intervention in real time.Read More

What are the capabilities of the Negri Bossi s850T-7460 series molding press?

The Negri Bossi s850T-7460 series molding machine fills the gap between existing 770 ton and 1500-ton presses and uses less energy to provide more tonnage pressure and tighter tolerances.Read More

How is Stereo Lithography (STL) used with PolyWorks Inspector as part of TQM?

By providing a clearer, more complete image of a piece, STL allows high standards of quality control.Read More