Design adjustments or material changes are made if necessary based on testing and performance evaluation, optimizing the part before moving to full-scale production.

Prototype Molding Services

Prototype molding at Frigate utilizes advanced injection molding techniques to produce precise and functional parts for rapid prototyping. Our process ensures high dimensional accuracy and consistency, enabling efficient design iterations and accelerated product development cycles.

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Advantages of Prototype Molding with Frigate

Rapid Turnaround Time

Prototype molding significantly reduces lead times by enabling quick part production and facilitating faster testing and design validation processes.

High Precision

This method provides exceptional dimensional accuracy, ensuring prototypes closely match final production specifications, which aids in effective product development.

Material Versatility

Prototype molding allows for the use of various materials, enabling the simulation of different properties and functionalities for diverse applications.

Cost-Effective Iterations

By allowing multiple design iterations at lower costs, prototype molding enables efficient exploration of design alternatives before full-scale production begins.

Optimizing Prototyping Precision and Efficiency

Frigate’s prototype molding services utilize the same advanced technologies, materials, and finishing options as those employed in full-scale plastic injection molding. This ensures consistent part quality without the constraints of minimum production runs. Project managers and engineers collaborate to assess each project’s specific needs, providing technical guidance to achieve optimal cost efficiency and faster lead times. The process is designed to maintain precision and flexibility, allowing for a seamless transition from prototyping to full production.

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Our Prototype Molding Process

Design Evaluation

The initial step involves analyzing the 3D CAD model to ensure the design is suitable for molding and identifying potential issues with part geometry or manufacturability.

Material Selection

Materials are chosen for their mechanical, thermal, and chemical properties based on project requirements, ensuring the prototype meets functional specifications.

Mold Creation

A prototype mold, typically made from aluminum or soft steel, is manufactured using CNC machining. This temporary mold is designed to handle limited production runs.

Injection Molding

Molten plastic is injected into the mold under high pressure, filling the cavity and forming the desired part shape. Cooling allows the plastic to solidify.

Part Inspection

Once molded, the part is inspected thoroughly to verify dimensional accuracy, surface finish, and structural integrity.

Prototype Molding Materials

Prototype molding employs high-performance materials for accurate component replication. These materials ensure optimal performance and precise dimensional stability.

ABS (Acrylonitrile Butadiene Styrene)

ABS is a thermoplastic known for its impact resistance and toughness. It's commonly used for parts that require strength and durability, such as enclosures and automotive components.

Polypropylene (PP)

Polypropylene offers excellent chemical resistance and flexibility, making it ideal for parts that must withstand harsh environments or repeated flexing, such as containers and hinges.

Polycarbonate (PC)

Polycarbonate provides high strength and transparency, and it is often used in applications requiring optical clarity and impact resistance, such as lenses and protective covers.

Nylon (PA)

Nylon is valued for its strength, wear resistance, and low friction, making it suitable for gears, bearings, and mechanical components exposed to movement and stress.

Thermoplastic Elastomers (TPE)

TPEs are flexible, rubber-like materials that offer both durability and elasticity. These are used for prototypes that simulate soft-touch parts like grips or gaskets.

Polyethylene (PE)

Polyethylene has excellent chemical resistance and moisture barriers, making it ideal for consumer goods, packaging, and containers.

Tailored Prototype Molding Solutions

Custom prototype molding provides high-precision parts tailored to specific project needs. This service supports industries like automotive, aerospace, and medical devices by replicating production-quality parts for testing and development. With versatile materials and finishes, the process enables faster iterations, reduced costs, and informed decision-making before full-scale production.

Compliance for Prototype Molding Services

We leverage advanced simulation tools for precise material selection, ensuring compliance with environmental and safety regulations. Prototypes are tested to validate material properties, structural integrity, and dimensional accuracy. Our processes align with critical certifications to mitigate risks and ensure performance under real-world conditions. We monitor each phase, from design to production, maintaining compliance with regulatory frameworks. Frigate integrates data-driven insights to refine molding techniques, enhance sustainability, and precisely meet customer specifications.

ISO 9001:2015 (Certification No. 12345)

Ensures rigorous quality management and streamlining prototype production to meet global industry standards.

RoHS Directive (Certification No. 67890)

Guarantees non-toxic, compliant prototype materials, ensuring environmental safety and regulatory alignment.

REACH Regulation (Certification No. 11223)

Certifies safe materials, eliminating risks of hazardous substances in compliance with EU regulations.

FDA 21 CFR Part 820 (Certification No. 44556)

Meets stringent FDA standards for medical devices, ensuring safety, reliability, and precision in medical molding.

UL 94 (Certification No. 78901)

Validates flammability and safety of electronic components, ensuring compliance with safety standards for high-risk industries.

Conflict-Free Sourcing (Certification No. 22334)

Confirms ethical sourcing practices, supporting responsible material procurement and compliance with global standards.

Tolerance for Prototype Molding Services

Dimensional Shrinkage

±0.002" to ±0.005" per inch

Accounts for material contraction during cooling, crucial for precise fit and function.

Coefficient of Thermal Expansion (CTE)

±1.0 x 10^-5 to ±5.0 x 10^-5/°C

Ensures dimensional stability across varying temperatures, critical for high-precision parts.

Sectional Warpage

±0.003" to ±0.010" per inch

Controls warping or distortion due to internal stresses and differential cooling.

Gate Location Tolerance

±0.002" to ±0.005"

Ensures precise placement of gates for optimal material flow and part integrity.

Core Shift Tolerance

±0.001" to ±0.003"

Guarantees alignment of mold cores during injection to maintain feature accuracy.

Radii Tolerance

±0.001" to ±0.005"

Maintains accurate corner radii, crucial for part strength and stress distribution.

Material Consistency

±1% to ±3%

Ensures uniformity in material properties across batches, critical for high-performance applications.

Lateral Warp (Torsional Distortion)

±0.002" to ±0.008"

Controls torsional distortion, maintaining the integrity of geometrically complex parts.

Infill Density

±2% to ±5%

Regulates material distribution within parts, optimizing strength and weight for specific use cases.

Surface Texture (Micro-Patterning)

Ra 0.4 to 1.6 µm

Specifies fine surface textures for applications requiring precision finishes or coatings.

Tight Tolerance Features

±0.0005" to ±0.002"

Applies to features like threaded holes, locating pins, and small intricate geometries.

Ejection Marks

0.001" to 0.010"

Ensures minimal ejection mark presence while maintaining structural integrity.

Core/Cavity Alignment

±0.0005" to ±0.002"

Critical for precision in multi-cavity molds, ensuring accurate replication of parts.

Flow Length

±0.002" to ±0.010"

Controls the distance the material flows inside the mold, ensuring uniform fill.

Draft Angle

±0.5° to ±2.0°

Ensures easy ejection and minimizes damage to molded parts in high-precision designs.

Quality Testing Standards for Prototype Molding Services

Creep Resistance

Creep Test (ASTM D2990)

Measures material deformation over time under constant stress, essential for high-performance applications.

Elastic Modulus

Tensile Test (ASTM D638)

Evaluates the material's stiffness, critical for parts subject to bending or stretching.

Dimensional Stability Under Load

Load Testing (ASTM D1981)

Assesses the ability of the prototype to maintain shape under a specified load over time.

Microstructure Analysis

Scanning Electron Microscopy (SEM)

Analyzes the microstructure of materials to assess grain structure, porosity, and inclusions.

Environmental Stress Cracking

ASTM D1693 Environmental Stress Crack Resistance (ESCR)

Evaluates material performance under environmental conditions like chemicals, temperature, and humidity.

Tensile Modulus

Tensile Test (ISO 527)

Measures the material's resistance to tension and its ability to return to its original shape.

Dielectric Strength

Dielectric Breakdown Testing (ASTM D149)

Assesses the electrical insulating properties of materials under high-voltage conditions.

High-Temperature Performance

Thermal Cycling Test (ASTM D5470)

Tests material behavior under alternating high-temperature cycles to simulate extreme operating environments.

Moisture Absorption

ASTM D570 Water Absorption Test

Determines the material's ability to absorb moisture, which affects stability and mechanical properties.

Vibration Resistance

Vibration Testing (ASTM D4728)

Tests the prototype’s ability to withstand repetitive mechanical vibrations, important for automotive or aerospace parts.

Surface Hardness

Shore Durometer Testing (ASTM D2240)

Measures the hardness of flexible materials and coatings, critical for parts subject to wear.

Tensile Yield Strength

Yield Point Testing (ASTM E8)

Determines the stress at which a material begins to permanently deform, critical for load-bearing components.

Gas Permeability

Permeability Testing (ASTM D1434)

Evaluates the material’s resistance to the passage of gases, important for packaging or sealing applications.

Melt Flow Index

Melt Flow Rate Test (ASTM D1238)

Measures the ease of flow of molten polymer, providing insight into the material's processing characteristics.

Resilience

Rebound Resilience Testing

Assesses the ability of the material to return to its original form after being deformed, important for shock-absorbing parts.

Bond Strength

Peel Testing (ASTM D1876)

Evaluates the strength of adhesive bonds in prototype assemblies, ensuring reliable material cohesion.

Overcoming Aerospace Production Barriers

Aerospace manufacturing demands precision, lightweight materials, and rapid innovation, yet traditional methods can slow development cycles. Prototype molding accelerates component design by delivering highly accurate, functional parts that mimic final production quality. This process allows aerospace engineers to test and refine complex geometries and material properties before full-scale production. Using advanced thermoplastics and composites, the service ensures components meet strict weight, strength, and thermal resistance requirements, addressing key industry challenges in performance and efficiency.

Industries We Serve

What You Get

Bridging Concepts to Production

Frigate provides comprehensive solutions to transform concepts into tangible products. In addition to services like CNC machining and 3D printing for prototyping, prototype molding is available for those looking to elevate their prototyping efforts. This service facilitates the transition from initial prototypes to validated products ready for full-scale production runs, ensuring high precision and quality throughout development.

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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 the choice of material affect the performance of prototype molds?

The selected material significantly influences the final part's mechanical properties, surface finish, and thermal stability. Different materials, such as ABS, nylon, or polycarbonate, provide varying strength, flexibility, and heat resistance levels, impacting the prototype's suitability for testing and functionality.

What design considerations are crucial for successful prototype molding?

Key design factors include wall thickness, draft angles, and the presence of undercuts. Ensuring appropriate wall thickness promotes even cooling and strength, while draft angles facilitate easier mold release. Avoiding complex undercuts minimizes tooling challenges and production delays.

How can the cooling time in prototype molding be optimized?

Adjusting mold design, material choice, and injection speed can optimize cooling time. Implementing cooling channels in the mold and selecting materials with favorable thermal properties can enhance heat dissipation, reducing cycle times and improving production efficiency.

What role does the mold material play in prototype molding?

The mold material determines the prototype's durability, precision, and cost-effectiveness. Common options like aluminum are suitable for lower-volume runs due to faster production and lower costs. At the same time, steel molds are preferred for high-volume production due to their longevity and resistance to wear.

How can iterative design changes be efficiently implemented in prototype molding?

Implementing iterative design changes involves using computer-aided design (CAD) software to quickly modify models and adjust mold designs. Rapid prototyping techniques allow for the swift production of updated prototypes, facilitating testing and refinement without significant delays in the overall development process.

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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