Consumer grade injection mold companies?

T Chap

I use an injection mold company that is good for some things, but I now see that there is a difference in companies. My guy can do very complex molds and run any amount, but he never makes anything with a finish that looks like a high end company does. Apple is an example of a very stylish molding process. The photo is something that is pretty good. Another thing I want in a company is someone who can take my basic cad drawings and convert it to the mold version drawing, so I do not have to trial and error on the actual end result 'working' after it is made. A good company already knows how it will turn out or fit together, and can avoid my oversights. Any suggestions on a company that can turn out evaluation quantities very fast at a consumer look? I prefer US based.

http://www.protomold.com/

This company looks interesting, 1495 starting prices are not bad.

pjv

Hi TChap;

One of my companies ( flexcim.ca ) has a plastics mold making and injection division, so we might be able to help, although we are located in Canada. Send us a sample or a CAD solid model file so we can give you an idea of what prices might be.

Cheers,

Peter (pjv)

tonyp12

One thing you should do to keep cost down, don't design where you need cut-in's during molding process.
E.g in a 3d world, the mold can be separated from the part without withdrawing some parts of the mold.

Phil Pilgrim (PhiPi)

I think it's important to go into any design with your eyes wide open. IOW, instead of handing a fabricator your dream design and saying , "Do what you have to do to make this," learn as much as you can about the process and its limitations beforehand. For example, "What are the boundaries for wall thickness? How much of a draft angle do you need? What do you need to do to avoid areas with visible shrinkage? When do you need to add reinforcing bulkheads? Where is the optimum place to put a parting line?" among just a few. These are all things that need to be planned for from the get-go -- not added by someone else as a fix to make a design manufacturable. Forewarned is forearmed, and educating yourself as much as you can before creating a design will save you money and grief in the long run.

-Phil

T Chap

Agreed Phil, I am well aware of the process, have designed several molds, and have production runs of various parts that are "behind the scenes" and the look is not critical. My problem is getting a nice cosmetic finish that looks slick. Some options will be matte, some glossy. The company I use now is great at making parts and assisting with design considerations, and I have spent many hours in their shop learning the entire process. They are just not in the business of high end looking parts.

The photo is one of the parts we make that does need to look nice, as it is mounted on a piece of elegant backpainted glass. In the raw it looks cheap. But, I sand it with 400, spray flat black on it, bake, sand, paint, until it gets a nice matte look to it which then becomes decent. I would prefer to not have to do anything, if that is even possible. Plenty of consumer products look really nice right out of the mold, so I know that there is a difference in processes for finishing. On this part, the EDM does contribute to finish, which in this case works out because I want it matte to contrast the high gloss black glass. Also, EDM is required for this type part.