Product development rarely follows a perfectly straight line. A prototype may reveal that a wall needs to be thicker, a hole needs to be smaller, or two components need a closer fit. These adjustments are a normal part of refining a design, but they can become more complicated once an injection mold has been built. […]
We all start somewhere. Even a business like Rex Plastics, rapidly closing in on its fiftieth anniversary, had humble beginnings. But starting a new product is about more than having a good idea. You also need to figure out how to turn that idea into a manufacturable product, manage upfront costs, and eventually produce enough […]
Regrind can be a useful option for injection molded plastic parts, but it is not automatically appropriate for every application. Reusing production scrap can reduce material waste and, in some cases, material costs. However, regrind can also behave differently from virgin resin depending on the plastic, its processing history, and the requirements of the finished […]
When a plastic component is designed and manufactured, each individual dimension has an acceptable range of variation. In a multi-part assembly, however, those small variations can combine and affect how the finished product fits and functions. This is known as tolerance stack up. Tolerance stack up is especially important for injection molded plastic assemblies because […]
Gates and parting lines are two of the most important design considerations in injection molding. Although they are often overlooked during the early stages of product development, both have a direct impact on part quality, cosmetic appearance, manufacturability, and tooling costs. Every injection molded part requires a gate to allow molten plastic to enter the […]
Ultrasonic welding is one of the most common methods for joining injection-molded plastic parts. It provides a fast, clean, and reliable way to create permanent assemblies without the use of adhesives, solvents, or mechanical fasteners. From medical devices to industrial equipment, ultrasonic welding creates strong, repeatable joints while supporting high-volume production. However, successful welding depends […]
Venting in injection molding is one of the most important yet often overlooked aspects of mold design. While much attention is typically given to part geometry, material selection, and tooling construction, proper venting plays a critical role in ensuring consistent part quality and efficient production. As molten plastic enters a mold cavity, the air already […]
Part manufacturers should always give careful consideration to the materials used in plastic part design, as this decision will have significant consequences for sink and warp in plastic injection-molded parts. Let’s take a look at what makes a part sink or warp, and some helpful advice for avoiding these in the injection molding and design […]
Since its inception in the 1960s, to its acceptance in the 1990s, the hot runner system has challenged tradition across the plastic injection molding business. With their increased cycle speed and decreased waste, hot runners are an attractive solution to many looking to diversify their injection molding process. What is a hot runner injection […]
What is a plastic hinge? In injection molding, a plastic hinge refers to a specialized feature designed within a plastic part to provide flexibility and allow rotational movement. The plastic hinge design allows it to endure repeated cycles of bending or flexing without causing permanent deformation or failure of the part. Using the inherent elasticity […]
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