Custom Injection Molding

Efficiently create hundreds or thousands of custom parts in many shapes, sizes, and materials with custom injection molding.

Custom Plastic Injection Molding

Injection molding is a great manufacturing technology that injections molten plastic into a mold then rapidly cooling to produce large amounts of parts repeatedly, for low costs. Located in the USA, our custom injection molding department is an agile team that can shift quickly based on your needs to run prototypes, bridge volumes or high-volume production. We handle projects in all different materials (ex. Nylon, ABS, PC, TPU) for all different industries (Aerospace, Medical, Consumer, Industrial) ranging in volumes from 1 to 1,000,000 parts or more per year.

Our injection mold presses range from 30 tons to 596 tons with barrels sizes of 3oz to 70oz for small, medium and large parts. With our agile mindset, our team can change tools and materials quickly without the downtime of other facilities.

Injection Molding Machine

Our project managers and engineering team work with a “one stop shop” mindset to ensure your product is designed for the right process, and if injection moldings is best for your requirements, then we will make the tooling, material, mold press and process work for your specific application.

Applications:

  • Low to high volume production
  • Small to large parts (up to 60oz shot size)
  • Wide range of available materials
  • Tight tolerance molding
  • Validated injection mold process
  • Low cost manufacturing option
  • Customized tooling and part production
  • Flexible manufacturing to ramp up production
  • No minimum order sizes
  • Part design reviews

Injection Tooling and Molding

Injection Molding Tooling

Plastic injection molding uses a combination of thermal principles and pressure to create the parts and components you need for your business. During plastic injection molding, plastic material is melted into a liquid state and then forced into a mold under high pressure. The part quickly cools and solidifies to create the unit.

At TTH and SAS, we believe in the “3-legged stool” approach to molding, that being that the design, tool and molding process all need to line up to get a good molded part. We work with our customers to provide tooling options based on the needs of their molded parts. We have tooling resources domestically and internationally depending on the requirements and needs of our customers, can provide full tools or MUD insert sets, and offer both aluminum and steel material options.

Here are the different types of tools available:

  • Rapid 3D Printed Tooling – This tooling option is used when companies need parts very fast for testing, prototyping or production. Tolerances and amount of parts out of a mold are not guaranteed. Parts are also restricted by size and material. Typically good for small parts with low temperature materials (TPU, ABS, PP, PE, etc)
  • Prototype Aluminum Tooling – This is a great option to get parts fast with lead times between 2-4 weeks depending on size and complexity. Molds are usually good for 2,500 parts or less and can be created in single, family or multi-cavities. Tools can then be used as bridge or production tools with special coatings t. In most cases, tools can continue to be used as bridge tooling or low volume production. Tool coatings are also an option to increase shot quantity.
  • Production Aluminum Tooling – In the niche markets of today, all parts do not need big, expensive steel tools. Over the last 20 years, we have worked with production aluminum tools and MUD inserts that allow for shorter lead times and reduced costs because molds, if designed right, can last for 10,000 to 20,000 shots. All tools can include automation, slides, multi-cavities and/or family setups.
  • Production Steel Tooling – When tolerances are tight and volumes are high, the best option is steel tooling. Steel tooling gives you the confidence of consistency from part to part at high volumes with tight tolerances as low as +/-0.001”. This is a great option when you need multiple cavities and fast cycle times to get lots of parts fast and at low costs. Typically this is a great option for tooling if you expect volumes over 20,000 parts.

To help design the right tool for the right molding material and injection press, we have the ability to do mold fill and mold flow analysis to better predict what will happen based on our tool design. Our company has also invested heavily in process validation and risk analysis, so we can understand the processing ranges of the parts we mold day in and day out. See the many different value added processes we use to support production.


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Injection Molding Materials

One of the many strengths associated with plastic injection molding is the wide variety of options available to manufacturers and designers for materials. It’s easy to become inundated in the material decision process, but with our experience, we can help guide you in choosing the best material for your application. Different industries have different needs when it comes to virgin, recycled, UL rated, FAR rated and food grade materials.

Injection Molding Parts

Here are some of the more common injection molding materials we use:

  • Nylon
  • PC/ABS blends
  • Polycarbonate
  • Polypropylene
  • Polyethylene
  • PBT
  • Glass fiber nylon
  • Polyvinyl chloride (PVC)
  • High-density polyethylene (HDPE)
  • Acrylonitrile butadiene styrene (ABS)
  • Acetal (Delrin)
  • Soft durometer materials (including Santoprene® and Sylvin®)

For finishing, we can customize your parts by treating the injection mold tooling for optically clear, high gloss, matte or any of the standard mold textures available. We can also custom color parts in many different ways including: coloring in-house, compounding or pre-coloring materials. Our team can also add any part decorations required including paint, labels, silk screening or pad printing to show off your brand.


What Our Partners Are Saying

In this competitive world with ever-changing technology, we need innovation partners that we can trust. Working with the team at The Technology House and Sea Air Space Machining & Molding over the past five years, I have grown to rely on their ability to deliver unique results and thus instruct my development teams to call them first. They constantly drive state-of-the-art solutions that exceed the expectations of our Medical Device Customers, delivering them at a great value!

- Brian W., General Manager, Medical Device Manufacturer

Get Your Product to Market

Our integrated approach to design, prototyping, and production allows you to bring your concept to market faster, more cost-effectively than virtually anyone else.

Bring Your Idea to Life