Blow Molding Services

Frigate’s blow molding technology produces durable plastic components with minimal scrap. We ensure precise control over part dimensions and wall thickness throughout production.

Our Clients

Advantages of Blow Molding Services

Rapid Tooling and Setup

The blow molding process allows for faster tooling and setup times than other molding techniques, speeding up production schedules.

Lightweight Components

Blow molding produces lightweight plastic parts without sacrificing strength, making it ideal for applications in the automotive and packaging industries.

Low Scrap Rate

The blow molding process has a low scrap rate due to precise material control, which reduces waste and improves sustainability.

Design Flexibility

Blow molding offers design flexibility, allowing for varied wall thicknesses, internal voids, and complex shapes, all in one part.

Custom Blow Molding Services for Precision and Efficiency

Inconsistent part quality and slow production can hinder manufacturing processes. Custom blow molding provides precise, high-quality parts with fast production cycles. This process ensures uniform wall thickness, complex geometries, and minimal material waste, making it suitable for high-volume runs. With a range of material options, custom blow molding meets specific technical requirements for durability and performance. It offers efficient, repeatable production while maintaining tight tolerances, making it ideal for industries requiring consistent and reliable plastic components.

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Our Blow Molding Process

Material Preparation

Thermoset materials are mixed with curing agents or hardeners before injection, ensuring they are ready for molding.

Injection into Mold

The prepared thermoset material is injected into a mold cavity under high pressure, ensuring complete filling.

Curing

Once the material fills the mold, it undergoes heat curing. This causes the thermoset material to chemically cross-link, hardening it permanently.

Cooling

After curing, the part is cooled in the mold. This helps solidify the material further, ensuring it retains its shape and strength.

Ejection

Once fully cured and cooled, the part is ejected from the mold. The ejection process is done carefully to avoid damage.

Post-Curing (Optional)

Some thermoset parts may undergo additional post-curing to enhance their physical properties. This step ensures maximum durability and performance.

Blow Molding Materials

Blow molding is a highly efficient manufacturing process for creating hollow parts. It offers precise control over part design, thickness, and production speed.

High-Density Polyethylene (HDPE)

HDPE offers an excellent strength-to-weight ratio, high impact resistance, and chemical durability. It is ideal for rigid containers and industrial applications, and it resists environmental stress and maintains shape under pressure.

Polyethylene Terephthalate (PET)

PET has superior dimensional stability, high clarity, and strong moisture and gas barriers. Due to its thermal resistance and recyclability, it is ideal for food and beverage packaging.

Polypropylene (PP)

PP is excellently resistant to chemicals, has low moisture absorption, and is highly resistant to heat. It’s used in automotive components and containers that require high-temperature performance and durability.

Polyvinyl Chloride (PVC)

PVC offers rigidity, UV resistance, and electrical insulation. It is commonly used for medical devices, piping, and weather-resistant containers, providing stability in harsh environments.

Acrylonitrile Butadiene Styrene (ABS)

ABS provides high-impact resistance and toughness, even at low temperatures. It is ideal for automotive parts, electrical enclosures, and consumer products that require strength and durability.

Nylon (Polyamide)

Nylon offers excellent wear resistance, low friction, and high-temperature stability. It is used in automotive, industrial, and electrical applications that require durable, high-performance parts.

Polystyrene (PS)

PS is lightweight, rigid, and easy to process. While commonly used for disposable packaging, it has limited impact and chemical resistance, making it suitable for low-stress applications.

Thermoplastic Elastomers (TPE)

TPE combines rubber-like flexibility with thermoplastic processing. It is used for durable, flexible parts like seals and gaskets, offering excellent abrasion resistance and low-temperature performance.

Efficient Cycle Time Reduction for Enhanced Productivity

Optimizing cycle time is essential for improving production efficiency while maintaining consistent part quality. Frigate addresses this through precise temperature control, advanced mold cooling systems, and optimized material flow management. By fine-tuning the mold design and cooling process, cycle time is reduced without compromising the integrity of the part. This approach allows for faster production rates while ensuring the desired mechanical properties and dimensional accuracy, increasing overall productivity and reducing operational costs.

Compliance for Blow Molding Services

Blow molding at Frigate meets specific technical certifications critical to material safety, production accuracy, and environmental standards. Each compliance ensures precise tolerances, chemical compatibility, and durability under operational conditions. This approach supports advanced manufacturing needs and regulatory obligations.

FDA 21 CFR 177.1520

Certifies polyethylene and polypropylene for direct food and medical contact, ensuring chemical resistance and hygienic material properties.

ISO 9001:2015

Enforces traceability and defect controls in manufacturing processes, ensuring consistent blow-molded product quality.

ASTM D256

Defines impact resistance for thermoplastics, ensuring materials meet performance standards for structural and safety-critical applications.

REACH (EC) No. 1907/2006

Regulates chemical exposure in plastics, prohibiting harmful additives and ensuring worker and consumer safety.

RoHS Directive 2011/65/EU

Limits hazardous substances, ensuring suitability for electronics and environmentally conscious industries.

UL 746C evaluates

UL 746C evaluates the long-term thermal aging of polymeric materials, ensuring performance under prolonged exposure to heat and stress.

ISO 14632

Specifies environmental requirements for blow molding, emphasizing energy efficiency and reduced waste.

Tolerance for Blow Molding Services

Parison Thickness Variance

±0.02 mm to ±0.10 mm

Controls the thickness of the extruded parison to ensure even wall thickness and minimal material waste.

Ovality of Circular Sections

±0.10 mm to ±0.50 mm

Ensures consistency in round features like bottle necks or containers to prevent deformation under load.

Melt Flow Rate Consistency

±0.5% of specified rate

Monitors resin flow during processing for uniform material distribution and structural integrity.

Draft Angle Precision

±0.5°

Controls draft angles to facilitate part ejection without surface defects or dimensional distortion.

Surface Flatness

±0.05 mm per 100 mm

Ensures flat surfaces remain within tolerance to prevent assembly issues or leakage in critical seals.

Weld Line Strength

±10% of nominal strength

Validates the integrity of weld lines formed during molding to withstand operational stresses.

Internal Pressure Tolerance

±1% of design pressure

Ensures molded parts can withstand specified internal pressures without failure for liquid or gas storage.

Flow Channel Uniformity

±0.1 mm

Maintains consistent channel dimensions in complex geometries to optimize material flow and cooling.

Radiused Corners

±0.05 mm to ±0.15 mm

Ensures precision in corner radii to enhance strength and reduce stress concentration points.

Mold Temperature Variance

±2°C

Monitors mold temperature uniformity to ensure dimensional accuracy and prevent surface imperfections.

Quality Testing Standards for Blow Molding Services

Parison Temperature Control

Infrared Thermography

Verifies uniform parison heating to avoid material inconsistencies and ensure optimal flow.

Residual Stress Analysis

Photoelastic Stress Analysis

Detects internal stresses in molded parts to prevent premature failure under operational loads.

Creep Resistance

Long-Term Load Testing

Measures deformation over time under sustained loads, ensuring durability for extended use.

Melt Fracture Examination

High-Speed Camera Analysis

Identifies defects during resin extrusion to optimize process parameters for smoother finishes.

Weld Line Integrity

Ultrasonic Testing

Assesses weld line strength and bonding quality in critical structural areas.

Volatile Organic Compounds (VOC)

Gas Chromatography-Mass Spectrometry (GC-MS)

Quantifies emissions to ensure compliance with environmental and health standards.

Part Fatigue Testing

Cyclic Load Testing

Simulates repeated stress to evaluate part performance under real-world operating conditions.

Heat Deflection Temperature (HDT)

ASTM D648 Heat Deflection Test

Determines material behavior under specified loads at elevated temperatures.

Optical Clarity

Spectrophotometry

Assesses light transmission for transparent or semi-transparent blow-molded parts.

Layer Adhesion Strength

Peel or Shear Testing

Evaluates bonding between multi-layer materials for strength and delamination resistance.

Vibration Resistance

Vibration Table Testing

Ensures part stability and integrity under dynamic load conditions.

Gas Permeability

ASTM D3985 Oxygen Transmission Rate Test

Measures barrier properties for gases to ensure suitability for food, beverage, or medical uses.

Optimizing Performance and Sustainability in Automotive Components

Balancing cost efficiency with high-performance standards in automotive manufacturing can be challenging. Blow molding offers a solution by enabling the production of lightweight, durable components with complex geometries. The process ensures precise control over material distribution and wall thickness, minimizing material waste and defects. Its fast production cycles meet tight manufacturing timelines while maintaining high-quality standards. Additionally, blow molding supports sustainability by using recyclable materials while ensuring the required strength and functionality for automotive components.

Industries We Serve

What You Get

Precision Control for Thin-Walled Parts with Maximum Strength

Ensuring high precision in thin-walled blow-molded parts is achieved through advanced mold engineering and precise control of material distribution. Frigate utilizes specialized techniques to control material flow and cooling rates, ensuring uniform wall thickness and structural integrity. These methods allow for the production of thin-walled components that meet stringent tolerance requirements while maintaining the necessary strength. This solution is particularly effective for industries like automotive and packaging, where high precision and durability are critical.

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What Our Customers Say about Frigate

I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and 3D Printing and take their ideas to manufacturing. One firm doing all kinds of Product Development!

Thank you so much for your great support so far. Overall, the sheet metal work of the Plotbot Pro was done in an awesome way.Special Mention: The powder coat looks cooler!

The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way!I personally believe the Frigate's way of IIOT enabled cloud platform with Al.

I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.

Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How do blow molding processes handle complex part geometries with tight tolerances?

Blow molding allows for precise control over wall thickness and part dimensions, ensuring complex geometries are accurately produced with tight tolerances. The process utilizes specialized molds and pressure regulation to maintain consistency throughout production.

What is the effect of material shrinkage during the blow molding process?

Material shrinkage is accounted for during mold design to ensure parts retain dimensional accuracy. Blow molding uses precise temperature control and mold compensation to minimize shrinkage, especially in larger or more intricate parts.

How does blow molding ensure uniform wall thickness across all molded parts?

Blow molding maintains consistent wall thickness by regulating air pressure during molding and optimizing material flow. This ensures uniformity, even in large or asymmetrical parts, reducing material waste and improving structural integrity.

What methods are used to improve the strength and durability of blow-molded parts?

Blow molding can improve strength through material selection, multi-layer designs, or post-processing techniques like heat treatment. Specific formulations can enhance impact resistance, tensile strength, and thermal stability, ensuring long-lasting performance.

How does blow molding handle challenges in recycling and material waste?

Blow molding minimizes material waste through precise material control and efficient molding cycles. Many blow-molded parts are made from recyclable materials, allowing for easy post-production recycling and reducing environmental impact.

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ