Thermoplastic Injection Molding Services

Frigate provides high-tolerance thermoplastic injection molding for complex, durable component designs. Our process uses controlled cooling and optimized fill rates for maximum material integrity.

Our Clients

Advantages of Thermoplastic Injection Molding Services

Consistent Part Repeatability

Precision molding techniques ensure each part is identical, maintaining uniformity and reducing variability in high-volume production runs.

Superior Heat Resistance

Thermoplastics withstand elevated temperatures, making them suitable for components in demanding applications, including automotive and electronic housings.

Reduced Material Waste

The injection process minimizes excess material, as only the required amount fills each mold, leading to cost-efficient and eco-friendly production.

Enhanced Structural Integrity

Controlled injection pressure and mold design ensure parts have excellent mechanical strength, supporting load-bearing applications without compromising material properties.

Enhance Component Quality with Custom Thermoplastic Injection Molding

Precision and material consistency are crucial for parts with complex designs and tight tolerances. Custom thermoplastic injection molding provides high-accuracy solutions for industries requiring reliable, high-quality components. It enables quick production cycles, supports a wide range of polymers, and minimizes material waste, reducing costs and improving sustainability. Advanced tooling and temperature control ensure excellent dimensional stability and smooth finishes, even in high-volume production.

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Our Thermoplastic Injection Molding Process

Material Selection

Thermoplastic pellets are chosen based on the final product's required properties, such as strength, flexibility, and heat resistance.

Melting and Plasticizing

The pellets are fed into a heated barrel, melting and plasticizing to achieve a smooth, flowable consistency.

Injection

The molten thermoplastic is injected into a mold cavity at high pressure, ensuring the material fills even intricate mold features.

Cooling

The mold cools to solidify the thermoplastic, helping the part retain its precise dimensions and structural integrity.

Ejection

Once solidified, the molded part is ejected from the mold by an ejector system, minimizing any potential for part deformation.

Finishing

The part may undergo secondary processes, like trimming or surface finishing, to meet specific quality and aesthetic requirements.

Thermoplastic Injection Molding Materials

Thermoplastic injection molding offers precision and versatility for complex part production. Its ability to meet strict performance, durability, and dimensional requirements is unmatched.

Polypropylene (PP)

Known for excellent chemical resistance and flexibility, polypropylene is lightweight & resistant to impact. This makes it ideal for parts that require durability under stress, like automotive components and consumer goods.

Polyethylene (PE)

Available in multiple densities, polyethylene is tough and resistant to moisture and chemicals. Due to its excellent barrier properties, it’s commonly used in packaging, containers, and plumbing applications.

Acrylonitrile Butadiene Styrene (ABS)

ABS offers high-impact resistance and strength with good dimensional stability. Its toughness and ease of molding make it suitable for automotive interiors, electronics housings, and consumer appliances.

Polycarbonate (PC)

Polycarbonate is known for its transparency and impact resistance. It also withstands high temperatures and UV exposure, making it ideal for optical lenses, lighting covers, and safety equipment.

Polyamide (Nylon)

Nylon exhibits high tensile strength, wear resistance, and low friction, making it suitable for mechanical parts like gears, bushings, and automotive components that need long-term durability.

Polyethylene Terephthalate (PET)

With excellent chemical resistance and rigidity, PET is commonly used for food containers and beverage bottles. Its transparency and strength also make it suitable for optical applications.

Polystyrene (PS)

Polystyrene is lightweight and easy to mold, offering good rigidity but limited flexibility. It’s often used in disposable items, packaging, and lightweight applications.

Thermoplastic Polyurethane (TPU)

TPU is highly elastic, wear-resistant, and flexible, making it a good choice for applications requiring flexibility and durability, such as seals, gaskets, and protective coatings.

Achieving Precision with High-Strength Alloys

Forming high-strength alloys is challenging due to inconsistent pressure and force. Frigate addresses this using advanced pneumatic systems to regulate pressure and speed, ensuring better material flow. Tooling and process parameters are customized for each alloy, applying optimal force for precise results. Simulations and testing predict material behavior, allowing for proactive adjustments and ensuring consistent quality, even with difficult alloys.

Compliance for Thermoplastic Injection Molding Services

Frigate’s thermoplastic injection molding process strictly follows industry compliance standards. We ensure precision, safety, and environmental responsibility with each part produced. Our focus on advanced technologies and top-tier materials guarantees that all components meet regulatory standards.

ISO 9001:2015

Ensures a robust Quality Management System for consistent, high-quality manufacturing processes.

RoHS Directive (EU) 2015/863

Restricts the use of hazardous substances in electrical and electronic equipment.

FDA 21 CFR Part 820

Certifies materials used in medical devices, ensuring safety and effectiveness in healthcare applications.

UL 94 V-0

Confirms compliance with stringent flammability safety standards for plastic materials.

REACH (EC) No. 1907/2006

Ensures chemical safety in materials used within the European market by restricting hazardous substances.

ISO 14001:2015

Verifies an effective Environmental Management System to reduce environmental impact.

IATF 16949:2016

Specifies quality management standards for automotive industry components, ensuring superior performance and reliability.

Tolerance for Thermoplastic Injection Molding Services

Gate Location Tolerance

±0.002 in (±0.051 mm)

Ensures precise positioning of the gate in relation to the part for consistent flow.

Ejection Pin Mark Location

±0.005 in (±0.127 mm)

Defines the accurate placement of ejection pin marks to ensure consistent part removal.

Cavity Pressure Distribution

±2%

Tolerance on cavity pressure to ensure uniform material distribution during injection.

Injection Speed

±3%

Precision in controlling the speed of injection to avoid defects like flow lines.

Mold Shrinkage

±0.002 in/in (±0.051 mm/mm)

Controls the dimensional change of the part during cooling, ensuring consistency.

Core & Cavity Alignment

±0.002 in (±0.051 mm)

Ensures precise alignment between core and cavity to avoid part distortion.

Flow Length Tolerance

±0.010 in (±0.254 mm)

Tolerance on the distance the plastic flows inside the mold to maintain part integrity.

Injection Temperature

±5°C

Ensures precise control over the injection molding temperature to avoid warping.

Cooling Rate

±1°C/min

Control over the cooling rate to prevent uneven cooling and ensure part consistency.

Draft Angle

±0.5°

Precision on the angle of draft to allow for easy part ejection without damage.

Part Warpage

±0.005 in (±0.127 mm)

Controls the part’s tendency to warp during cooling, ensuring accuracy and stability.

Rib Thickness

±0.010 in (±0.254 mm)

Tolerance on the thickness of ribs for proper strength without risk of breakage.

Surface Texturing

Ra ≤ 0.2 µm

Specifies the roughness of molded surfaces for both aesthetic and functional parts.

Mold Surface Finish

Ra ≤ 0.1 µm

Ensures high-quality surface finish in areas that require detailed texturing.

Material Consistency

±0.1%

Ensures that material properties, like viscosity, are consistent for uniform parts.

Quality Testing Standards for Thermoplastic Injection Molding Services

Mold Flow Behavior

Mold Flow Simulation

Predicts how the material flows inside the mold, optimizing part design and reducing defects.

Vicat Softening Point

ASTM D1525 (Vicat Softening Test)

Measures the temperature at which the material begins to soften under a specified load.

Creep Resistance

ASTM D2990 (Creep Test)

Assesses the material's tendency to deform under constant load over time.

Moisture Absorption

ASTM D570 (Water Absorption Test)

Tests the rate at which a material absorbs moisture, affecting its mechanical properties.

Tensile Modulus

ASTM D1987 (Tensile Modulus Test)

Measures the material’s stiffness under tension to understand its deformation behavior.

Flammability Resistance

UL 94HB, V-0 (Flammability Test)

Tests the material’s ability to resist burning when exposed to flame.

Thermal Conductivity

ASTM E1952 (Thermal Conductivity Test)

Measures the material’s ability to conduct heat, important for heat-sensitive applications.

Gas Permeability

ASTM D1434 (Gas Permeability Test)

Measures the rate at which gases permeate through the molded material.

Thermal Expansion Coefficient

ASTM E831 (Thermal Expansion Test)

Measures how much the material expands or contracts with temperature changes.

Stress Relaxation

ASTM D6299 (Stress Relaxation Test)

Evaluates how the material’s stress decreases over time under a constant strain.

Tensile Elongation at Break

ASTM D638 (Tensile Test)

Measures how much the material can elongate before breaking, indicating ductility.

Surface Hardness

Shore D Hardness Test (ASTM D2240)

Assesses the hardness of the molded material to ensure it meets the specified durability.

Dimensional Stability Under Load

ASTM D5932 (Load Deflection Test)

Evaluates the part's ability to maintain shape under a defined load over time.

Stress Cracking Resistance

ASTM D1693 (Environmental Stress Crack Resistance Test)

Measures the material's resistance to cracking under stress in harsh environments.

Weld Line Strength

ASTM D5420 (Weld Line Strength Test)

Tests the strength of the part at weld lines to ensure that mold flow paths are optimized.

Optimizing Automotive Component Manufacturing

The automotive industry demands cost-effective, high-quality components with complex geometries and tight tolerances. Thermoplastic injection molding offers a solution by enabling efficient production of lightweight, durable parts that meet these requirements. Frigate utilizes this process, ensuring precise molding and rapid production cycles. With advanced control over material flow and temperature, Frigate consistently delivers parts with excellent surface finishes and minimal waste. The ability to work with various thermoplastic materials, from high-performance plastics to specialized composites, meets the diverse needs of automotive applications. This enhances both performance and production efficiency.

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Industries We Serve

What You Get

Maximizing Tool Life and Reducing Downtime

Pneumatic systems often cause rapid die wear due to repetitive pressure. Frigate counters this by selecting durable, wear-resistant die materials and incorporating advanced cooling systems to reduce thermal expansion. Optimized cycle times and controlled pressure minimize stress on dies, extending tool life and reducing maintenance needs. Real-time monitoring further reduces downtime, ensuring consistent production and improved operational efficiency.

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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 does Frigate control the melt flow rate for consistent thermoplastic injection molding?

Frigate uses precise barrel heating, optimized screw speeds, and real-time melt flow monitoring to ensure uniformity and prevent variations in part quality.

What methods does Frigate use to prevent warping and distortion in thermoplastic molded parts?

Frigate controls cooling rates, optimizes mold design, and carefully selects materials to reduce internal stresses and prevent warping during the cooling phase.

How does Frigate manage the thermal cycling of molds in high-volume thermoplastic injection molding?

Frigate implements efficient cooling channels and thermal management systems to maintain consistent mold temperatures, improving cycle time efficiency and durability.

What quality control measures does Frigate use for material consistency across multiple injection molding runs?

Frigate employs continuous monitoring, automated inspection, and strict material traceability to ensure that each batch meets specifications for consistent part quality.

How does Frigate handle the challenges of producing thin-walled thermoplastic parts with high structural integrity?

Frigate optimizes injection pressure profiles and cooling systems to ensure rapid solidification and consistent wall thickness, maintaining strength in thin-walled parts.

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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