Production Molding Services
Frigate employs advanced production molding techniques for precise dimensions and superior surface finishes. Our cutting-edge equipment ensures rapid cycle times and efficient material use for optimal performance.Â
Our Clients
Advantages of Production Molding with Frigate
High-Dimensional Accuracy
Production molding achieves tight tolerances, ensuring parts meet exact specifications. This accuracy is critical for functional and assembly requirements.
Efficient Material Utilization
The process minimizes waste, maximizing the use of raw materials. This efficiency lowers costs and reduces environmental impact during production.
Rapid Cycle Times
Production molding allows for a quick turnaround between cycles. This speed enables higher output and faster delivery for large-scale manufacturing needs.
Consistent Quality
Automated processes in production molding ensure uniformity in every batch. This consistency enhances product reliability and performance across various applications.
Advanced Thermal Management Techniques
Maintaining optimal temperature during the production molding is vital for proper material flow and part quality. Effective thermal management ensures precise temperature control of the mold and injected material. Low temperatures can hinder material flow, leading to incomplete fills and defects, while excessive heat can cause warping and degrade material properties. Frigate utilizes advanced temperature control systems to monitor and adjust thermal conditions in real time, minimizing inconsistencies and reducing cycle times to ensure components meet strict quality standards.Â
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Our Production Molding Process
The process begins with choosing the appropriate material based on the required properties and application requirements. Common options include thermoplastics, thermosetting plastics, and elastomers.Â
A mold is designed to match the component's specifications. This involves computer-aided design (CAD) software to create detailed models. The mold is then fabricated using precision machining techniques.Â
The selected material is heated to its melting point or a pliable state, allowing it to flow easily. This heating is critical for ensuring proper material behavior during injection.Â
The heated material is injected into the mold cavity under high pressure. This step ensures that the material fills all intricate areas of the mold, creating the desired shape.Â
After injection, the mold is cooled to allow the material to solidify. This step is essential for achieving dimensional stability and the desired mechanical properties.Â
Once the material has hardened, the mold is opened, and the finished component is ejected. Additional finishing processes, such as trimming or surface treatment, may be performed to meet final specifications.
Production Molding Materials
Production molding materials vary across plastics, metals, rubber, composites, ceramics, and foams, each offering distinct properties suited to specific applications.
Versatile and easy to process, thermoplastics like polypropylene and polyethylene can be reshaped multiple times. They are widely used for their chemical resistance and durability in automotive and consumer goods.Â
 Thermosetting plastics, such as epoxy and phenolic resins, harden permanently when heated. They offer excellent heat resistance and strength, making them suitable for high-performance applications like electrical components.Â
Rubber-like elastomers, including silicone and polyurethane, provide significant flexibility and elasticity. Thanks to their resistance to chemicals, heat, and aging, they are ideal for seals and gaskets.Â
Metal injection molding (MIM) uses metal powders, such as stainless steel and titanium, for precision components. This process enables complex geometries and superior mechanical properties for automotive and medical applications.Â
Composite materials combine two or more materials to achieve enhanced properties. Fiberglass and carbon fiber reinforced polymers offer high strength-to-weight ratios, making them suitable for aerospace and high-performance automotive parts.Â
Made from renewable resources, bio-based plastics like polylactic acid (PLA) are biodegradable. They serve as eco-friendly alternatives in packaging and disposable products, reducing environmental impact.Â
High-performance polymers like PEEK and polyimide provide exceptional thermal stability and chemical resistance. They are ideal for demanding aerospace, medical devices, and electronics applications.Â
Tailored Custom Production Molding Solutions
Custom production molding provides precise, tailored solutions for specific project needs. It ensures accurate dimensional control and consistent quality while accommodating complex geometries. Advanced techniques enhance efficiency, minimize waste, and reduce costs. With scalable production for various volumes, timely delivery is assured. This adaptability fosters innovations, improving performance and functionality while offering businesses greater flexibility in their manufacturing processes.Â
Compliance for Production Molding Services
Precision engineering and strict regulatory frameworks drive compliance for production molding at Frigate. Every production stage is optimized to meet advanced industry standards, ensuring high performance. Frigate’s operations integrate cutting-edge technology, materials, and testing methods to meet compliance mandates. This minimizes risk while maximizing efficiency and product integrity. Regulatory alignment is central to Frigate’s commitment to reliable, sustainable, and safe molded components across industries.Â
Streamlined quality management system focusing on continuous process optimization and defect reduction in production.Â
Strictly adherence to materials restriction ensures zero harmful substances in electronics and consumer goods.
Ensures flame retardancy of molded materials, critical for electrical components in high-risk environments.Â
Defines cell structure and performance for elastomeric molded components, ensuring mechanical integrity under stress.Â
Certifies molding materials meet stringent standards for non-toxicity in food-grade applications.Â
Monitors chemical compliance in production, ensuring that no harmful substances are in products sold within the European market.Â
Automotive industry-focused certification ensuring strict product traceability, process control, and defect prevention.Â
Environmental management standards ensure minimized waste, energy efficiency, and sustainability throughout molding.Â
Tolerance for Production Molding Services
Accounts for the contraction of material as it cools and solidifies in the mold.Â
Ensures minimal marks left on parts during the ejection process for aesthetic quality.Â
Ensures the separation between the two halves of the mold is precise and aligned.Â
Pressure range used to inject material into the mold, affecting material flow and fill.Â
Controls the rate at which material is injected into the mold cavity, affecting part density and fill.Â
Ensures consistent pressure within the cavity for uniform material distribution.Â
Temperature range for molten material, ensuring optimal flow and molding characteristics.Â
Time required for the mold to cool sufficiently before part ejection, impacting cycle time.Â
Size of vents to allow air escape during injection, preventing voids or defects.Â
Ensures uniform flow of material to all cavities, minimizing differences in part dimensions.Â
Tolerance for surface imperfections, such as flash or sink marks, affecting cosmetic quality.Â
Measurement of the material’s ability to withstand pulling forces without breaking.Â
The material's resistance to sudden impacts, crucial for durable molded parts.Â
Measurement of material hardness, indicating wear resistance and durability.Â
Accounts for slight dimensional changes during mold cooling and part ejection.Â
Ensures the material fills the mold cavity efficiently without premature cooling or material defects.Â
Variance in glass fiber distribution within the material, impacting part strength.Â
Ensures molded parts maintain consistent weight for uniform performance.Â
Quality Testing Standards for Production Molding Services
Assesses mold for cracks, wear, or imperfections to prevent part defects.Â
Evaluates how the material withstands repeated stress or deformation cycles.Â
Measures the part's ability to resist electromagnetic interference in sensitive applications.Â
Tests material's resistance to cracking when exposed to chemicals and stress.Â
Measures the strength of bonded joints between parts or materials.Â
Measures the friction between two surfaces to assess wear resistance.Â
Measures the material’s ability to conduct heat, important for thermal management in components.Â
Measures material's ability to return to its original shape after compression.Â
Assesses the material’s ability to absorb vibrations in applications like automotive parts.Â
Measures deformation under a sustained load over time, critical for structural components.Â
Tests the material’s ability to absorb moisture, impacting stability and performance.Â
Determines the temperature at which a material becomes brittle under stress.Â
Measures how the material’s dimensions change with temperature variations.Â
Determines the stress at which a material begins to permanently deform.Â
Tests how easily gases pass through a material, critical for sealed applications.Â
Measures the material's ability to return to its original shape after deformation.Â
Tests material performance under UV light exposure to simulate environmental aging.Â
Tests the material's ability to resist wear under abrasive conditions.Â
Harnessing Production Molding to Transform Automotive Component Design
The automotive industry faces challenges like the need for lightweight materials, complex designs, and strict quality standards. Production molding efficiently creates intricate, durable components that enhance fuel efficiency and performance. With precise mold design, assembly time and costs are reduced while various materials are accommodated for innovative designs. Overall, production molding boosts manufacturing efficiency and enables the rapid development of high-quality automotive parts.Â
Industries We Serve
What You Get
↓ 7-8%
OPS COST
↓ 2-3%
COGM
3X
Aggregation
↑ 25%
Machinery Utilisation
↓ 50%
Expedition
↑ 30%
Frigater Revenue
Achieving High-Quality Surface Finish in Production Molding
Achieving surface finish without defects is challenging, especially for complex geometries. Variations in mold surface treatments and molding conditions can lead to imperfections. Frigate addresses these issues through advanced mold treatments and precise process controls, optimizing mold design and materials to minimize defects. Rigorous quality assurance protocols ensure that all components meet stringent specifications, delivering reliable and aesthetically pleasing results.Â
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Having Doubts? Our FAQ
Check all our Frequently Asked Question
Material viscosity affects how easily a polymer flows into the mold. Lower viscosity improves filling but may lead to defects, while higher viscosity enhances detail but can slow down cycle times.Â
Mold temperature directly impacts cooling rates and the crystallization of materials. Proper temperature control ensures uniform cooling, minimizing warping and defects in the final product.Â
Multi-cavity molds allow for simultaneous production of multiple parts, significantly increasing output and efficiency. This setup reduces cycle time and production costs while maintaining consistent quality across components.Â
Gate design and placement influence how material enters the mold. Strategic placement can optimize flow, reduce defects like air traps, and improve overall fill patterns, enhancing the final component's quality.Â
The mold's surface finish affects release properties and the quality of the molded part. A smoother mold surface reduces friction, facilitating easier part ejection and minimizing surface defects on the final product.Â
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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. ã…¤
