Top Nine Materials used for Injection Molding and Over molding in Plastic Industry

At Filium we support multiple industries with material supplier specialist and CM for parts manufacturing. Here are the list of materials we can supply and manufacture for your existing or new design from prototyping to mass production. 

1. Polypropylene (PP)

• Properties: Lightweight, good chemical resistance, fatigue resistance.
• Applications: Automotive parts, containers, medical devices, packaging.

Polypropylene (PP) is a versatile thermoplastic polymer used in a variety of applications due to its unique properties, including chemical resistance, durability, and cost-effectiveness.

Properties of Polypropylene

• Lightweight: Offers high strength-to-weight ratio.
• Chemical Resistance: Resistant to acids, alkalis, and solvents.
• Thermal Resistance: Can withstand high temperatures without deformation.
• Flexibility: Maintains flexibility over a wide temperature range.
• Fatigue Resistance: Withstands repeated stress and deformation.

Applications of Polypropylene

1. Automotive Industry

• Components: Bumpers, dashboards, interior trims, and battery cases.
• Advantages: Lightweight, reduces vehicle weight, improving fuel efficiency.

2. Packaging

• Containers: Food storage containers, yogurt cups, bottle caps.
• Films: Used for food packaging films and labels.
• Benefits: Provides excellent barrier properties, keeping products fresh.

3. Textiles

• Non-woven Fabrics: Used in diapers, sanitary products, and surgical masks.
• Carpets and Rugs: Durable and stain-resistant fibers.
• Advantages: Lightweight, moisture-wicking, and resistant to staining.

4. Medical Applications

• Syringes: Disposable syringes and other medical devices.
• Lab Equipment: Petri dishes and beakers.
• Properties: Sterilizable and resistant to chemicals.

5. Housewares

• Products: Storage bins, kitchenware, and furniture.
• Advantages: Durable, lightweight, and available in various colors and designs.

6. Electrical Components

• Insulation: Wire and cable insulation.
• Components: Electrical connectors and casings.
• Benefits: High electrical resistance and flame retardancy.

7. Industrial Applications

• Pipes: Used for plumbing and irrigation systems.
• Sheets and Films: Used in industrial packaging and protective covers.
• Advantages: Corrosion-resistant and easy to install.

Environmental Impact and Sustainability

Polypropylene is recyclable and often used in eco-friendly applications. Efforts are being made to enhance recycling processes to reduce environmental impact.

Conclusion

Polypropylenes diverse properties make it a valuable material in numerous industries, from automotive to medical. Its adaptability, durability, and cost-effectiveness ensure its continued use and development in future applications.

2. Acrylonitrile Butadiene Styrene (ABS)

• Properties: Strong, impact-resistant, easily machined.
• Applications: Electronic housings, automotive components, consumer goods.

Acrylonitrile Butadiene Styrene (ABS) is a popular thermoplastic polymer known for its excellent mechanical properties, including toughness, impact resistance, and ease of fabrication.

Properties of ABS

• High Impact Resistance: Withstands shocks and drops.
• Durability: Resistant to wear and tear.
• Heat Resistance: Can endure high temperatures without deforming.
• Good Machinability: Easily molded and processed.
• Glossy Finish: Provides a smooth surface suitable for various applications.

Applications of ABS

1. Automotive Industry

• Components: Dashboards, trims, bumpers, and interior panels.
• Advantages: Lightweight, durable, and cost-effective, improving fuel efficiency.

2. Consumer Electronics

• Casings: Laptop covers, smartphone cases, and remote controls.
• Benefits: Provides a sturdy and aesthetic exterior, protecting internal components.

3. Toys

• Products: LEGO bricks, action figures, and educational toys.
• Properties: Safe, non-toxic, and capable of being molded into intricate shapes.

4. Household Appliances

• Applications: Vacuum cleaners, kitchen appliances, and power tool housings.
• Advantages: High durability and resistance to impact and heat.

5. 3D Printing

• Uses: Widely used filament in 3D printing for prototyping and creating models.
• Benefits: Easy to print, sand, and paint, offering a smooth finish.

6. Medical Applications

• Equipment: Nebulizers, inhalers, and various medical devices.
• Properties: Sterilizable and resistant to many chemicals.

7. Construction

• Applications: Pipes, fittings, and protective headgear.
• Advantages: Robust and able to withstand harsh environmental conditions.

Environmental Considerations

While ABS is not biodegradable, it is recyclable. Recycling efforts help minimize its environmental impact by reducing waste.

Conclusion

ABS is a versatile and valuable material across many industries due to its toughness, impact resistance, and ease of use. Its applications range from consumer electronics to automotive components, making it indispensable in modern manufacturing.

3. Polyethylene (PE)

• Properties: High ductility, impact resistance, moisture resistance.
• Applications: Bottles, plastic bags, toys, household goods.

Polyethylene (PE) is one of the most widely used thermoplastic polymers, known for its versatility, chemical resistance, and durability.

Properties of Polyethylene

• Lightweight: Low density.
• Chemical Resistance: Resistant to most acids and bases.
• Moisture Resistance: Excellent barrier properties against moisture.
• Flexibility: Maintains flexibility even at low temperatures.
• Impact Resistance: High resistance to impact and abrasion.

Applications of Polyethylene

1. Packaging Industry

• Products: Plastic bags, shrink wraps, and stretch films.
• Advantages: Cost-effective, moisture barrier, and lightweight.

2. Containers and Bottles

• Applications: Milk jugs, detergent bottles, and water containers.
• Benefits: Durable, recyclable, and safe for food contact.

3. Piping and Plumbing

• Uses: Water pipes, gas pipes, and irrigation systems.
• Advantages: Corrosion-resistant and easy to install.

4. Household Goods

• Products: Kitchenware, cutting boards, and storage bins.
• Properties: Easy to clean, durable, and available in various colors.

5. Agriculture

• Applications: Greenhouse films, mulch films, and silage wraps.
• Benefits: Protects crops, conserves moisture, and enhances growth.

6. Medical Applications

• Uses: Medical tubing, prosthetics, and packaging for sterile products.
• Advantages: Biocompatible and resistant to chemicals.

7. Textiles

• Products: Synthetic fibers for clothing, ropes, and nets.
• Properties: Lightweight, moisture-wicking, and strong.

Types of Polyethylene

• Low-Density Polyethylene (LDPE): Flexible, used in plastic bags and film applications.
• High-Density Polyethylene (HDPE): More rigid, used in containers and piping.
• Ultra-High Molecular Weight Polyethylene (UHMWPE): Extremely tough, used in medical devices and high-strength applications.

Conclusion

Polyethylenes versatility and beneficial properties make it an essential material across various industries, from packaging to medical applications. Its widespread use is due to its adaptability, durability, and cost-effectiveness.

4. Polystyrene (PS)

• Properties: Rigid, clear, good insulation properties.
• Applications: Disposable cutlery, CD cases, insulation materials.

Polystyrene (PS) is a versatile thermoplastic polymer known for its ease of use, cost-effectiveness, and variety of applications.

Properties of Polystyrene

• Lightweight: Low density.
• Rigid and Strong: Provides structural stability.
• Thermal Insulation: Good insulating properties.
• Moisture Resistance: Acts as a barrier to moisture.
• Easy to Mold: Can be easily shaped and fabricated.

Applications of Polystyrene

1. Packaging Industry

• Products: Foam cups, food containers, and protective packaging.
• Benefits: Lightweight, insulates temperature, and protects fragile items.

2. Construction

• Applications: Insulation boards, wall panels, and roofing.
• Advantages: Provides thermal insulation and reduces energy costs.

3. Consumer Goods

• Products: Disposable cutlery, plates, and CD cases.
• Properties: Inexpensive, durable, and easy to mold into various shapes.

4. Medical Industry

• Uses: Petri dishes, test tubes, and other laboratory equipment.
• Benefits: Sterilizable, clear, and chemically resistant.

5. Electronics

• Applications: Casings for electronics and appliances.
• Advantages: Provides structural support and electrical insulation.

6. Toys

• Products: Model kits, puzzles, and various playsets.
• Properties: Safe, lightweight, and easy to color.

7. Arts and Crafts

• Uses: Foam sheets and beads for crafts and DIY projects.
• Benefits: Easy to cut, shape, and decorate.

Types of Polystyrene

• General Purpose Polystyrene (GPPS): Clear and rigid, used for food containers and jewel cases.
• High Impact Polystyrene (HIPS): Impact-resistant, used for appliance housings and toys.
• Expanded Polystyrene (EPS): Lightweight foam, used for packaging and insulation.
• Extruded Polystyrene (XPS): Denser foam, used for insulation in construction.

Conclusion

Polystyrenes diverse applications make it an essential material in many industries. Its properties, such as insulation, durability, and ease of fabrication, contribute to its widespread use in packaging, construction, and consumer goods.

5. Polyamide (Nylon)

• Properties: High strength, abrasion resistance, good thermal resistance.
• Applications: Gears, bearings, automotive parts, textiles.

Polyamide, commonly known as nylon, is a versatile synthetic polymer widely used across various industries due to its excellent mechanical properties and durability.

Properties of Polyamide

• High Strength: Exceptional tensile strength and durability.
• Abrasion Resistance: Resistant to wear and friction.
• Chemical Resistance: Resistant to oils, solvents, and chemicals.
• Thermal Stability: Maintains properties under high temperatures.
• Lightweight: Offers a high strength-to-weight ratio.

Applications of Polyamide

1. Automotive Industry

• Components: Engine covers, gears, bearings, and interior trims.
• Benefits: Lightweight, reducing overall vehicle weight and improving fuel efficiency.

2. Textiles

• Uses: Clothing, hosiery, sportswear, and swimwear.
• Advantages: Strong, elastic, moisture-wicking, and resistant to wear.

3. Industrial Applications

• Products: Conveyor belts, hoses, and fasteners.
• Properties: High strength and resistance to abrasion and chemicals.

4. Consumer Goods

• Items: Kitchen utensils, toothbrushes, and sporting equipment.
• Benefits: Durable, impact-resistant, and available in various colors.

5. Electronics

• Applications: Cable insulation and circuit board components.
• Advantages: Electrical insulation properties and resistance to heat.

6. Medical Devices

• Uses: Surgical sutures, catheter tubes, and prosthetic devices.
• Benefits: Biocompatible, flexible, and sterilizable.

7. 3D Printing

• Applications: Prototyping and functional parts.
• Advantages: High strength, flexibility, and ease of printing.

Conclusion

Polyamides combination of strength, flexibility, and resistance to wear and chemicals makes it a crucial material in numerous industries. Its applications range from automotive components to textiles, showcasing its versatility and utility in everyday products.

6. Polycarbonate (PC)

• Properties: High impact resistance, optical clarity, heat resistance.
• Applications: Eyeglass lenses, safety helmets, automotive parts.

Polycarbonate (PC) is a high-performance thermoplastic known for its transparency, durability, and impact resistance. Its versatility makes it suitable for various applications.

Properties of Polycarbonate

• High Impact Resistance: Extremely tough and shatter-resistant.
• Transparency: Excellent optical clarity.
• Heat Resistance: Can withstand high temperatures.
• Lightweight: High strength-to-weight ratio.
• UV Resistance: Resists degradation from UV exposure.

Applications of Polycarbonate

1. Automotive Industry

• Components: Headlight lenses, interior and exterior trims.
• Benefits: Lightweight, durable, and impact-resistant, improving safety and efficiency.

2. Electronics

• Products: Smartphone cases, laptop casings, and optical discs (CDs, DVDs).
• Advantages: Provides protection and durability, while maintaining a sleek appearance.

3. Construction

• Uses: Skylights, roofing panels, and glazing.
• Benefits: Transparent and lightweight, providing natural light and impact resistance.

4. Medical Applications

• Devices: Surgical instruments, medical tubing, and safety glasses.
• Properties: Sterilizable, biocompatible, and durable.

5. Safety Equipment

• Applications: Safety goggles, face shields, and helmets.
• Benefits: High impact resistance, ensuring protection in hazardous environments.

6. Consumer Goods

• Products: Water bottles, food containers, and eyewear lenses.
• Advantages: Durable, reusable, and resistant to shattering.

7. Optics

• Applications: Camera lenses, optical lenses, and protective screens.
• Benefits: Provides clarity and durability while being lightweight.

Conclusion

Polycarbonates combination of durability, transparency, and impact resistance makes it an essential material in a wide range of industries. Its applications, from automotive components to consumer goods, highlight its versatility and importance in modern manufacturing.

7. Polyethylene Terephthalate (PET)

• Properties: Strong, impact-resistant, moisture barrier.
• Applications: Beverage bottles, food containers, synthetic fibers.

Polyethylene Terephthalate (PET) is a popular thermoplastic polymer known for its strength, lightweight properties, and recyclability. It is widely used in various industries due to its excellent performance characteristics.

Properties of PET

• Strength and Durability: High tensile strength and impact resistance.
• Lightweight: Ideal for packaging applications.
• Chemical Resistance: Resistant to acids and solvents.
• Clarity: Excellent transparency for visual appeal.
• Barrier Properties: Effective barrier against gases and moisture.

Applications of PET

1. Packaging Industry

• Beverage Bottles: Widely used for water, soft drinks, and juices.
• Food Containers: Used for jars, trays, and clamshell packaging.
• Benefits: Lightweight, shatterproof, and maintains product freshness.

2. Textiles

• Synthetic Fibers: Used in clothing, upholstery, and carpeting.
• Advantages: Durable, wrinkle-resistant, and quick-drying.

3. Automotive Industry

• Components: Seat fabrics, seatbelts, and interior trims.
• Benefits: Lightweight and strong, contributing to fuel efficiency.

4. Electronics

• Applications: Electrical insulation and casings for electronic devices.
• Properties: Provides durability and resistance to heat and chemicals.

5. Medical Applications

• Uses: Packaging for pharmaceuticals and medical devices.
• Advantages: Safe, sterile, and resistant to contamination.

6. 3D Printing

• Filaments: Used for creating durable and flexible parts.
• Benefits: Easy to print and recyclable.

Environmental Impact

• Recyclability: PET is highly recyclable and often used in the production of new bottles and textiles.
• Sustainability Efforts: Increasing use of recycled PET (rPET) in various products to reduce environmental impact.

Conclusion

Polyethylene Terephthalates combination of strength, clarity, and recyclability makes it an essential material in numerous industries. From packaging to textiles, its versatile applications highlight its importance in everyday products.

8. Thermoplastic Elastomers (TPE)

• Properties: Flexible, rubber-like, easy to process.
• Applications: Grips, seals, automotive parts, medical devices.

Thermoplastic Elastomers (TPE) are a class of polymers that combine the elasticity of rubber with the processing advantages of plastics. They are known for their versatility and wide range of applications.

Properties of TPE

• Flexibility: Elastic and stretchable.
• Durability: Resistant to abrasion and impact.
• Temperature Resistance: Performs well in a variety of temperatures.
• Recyclability: Can be reprocessed and reused.
• Chemical Resistance: Resistant to many chemicals and oils.

Applications of TPE

1. Automotive Industry

• Components: Seals, gaskets, and weatherstripping.
• Benefits: Provides flexibility, durability, and resistance to temperature extremes.

2. Consumer Goods

• Products: Grips for toothbrushes, kitchen utensils, and razors.
• Advantages: Soft touch, comfortable, and slip-resistant.

3. Medical Applications

• Uses: Tubing, syringe plungers, and medical grips.
• Benefits: Biocompatible, sterilizable, and flexible.

4. Electronics

• Applications: Cable insulation, connectors, and protective cases.
• Properties: Provides insulation and flexibility while being resistant to abrasion.

5. Footwear

• Uses: Shoe soles, insoles, and straps.
• Benefits: Provides cushioning, flexibility, and durability.

6. Sporting Goods

• Products: Grips for sports equipment, protective gear, and exercise bands.
• Advantages: Durable, flexible, and comfortable to use.

7. Industrial Applications

• Uses: Seals, hoses, and vibration dampeners.
• Benefits: Provides excellent resistance to chemicals and wear.

Conclusion

Thermoplastic Elastomers offer a unique combination of flexibility, durability, and ease of processing. Their wide range of applications, from automotive parts to medical devices, demonstrates their importance in various industries, providing both functionality and comfort.

9. Polyvinyl Chloride (PVC)

• Properties: Durable, chemical resistance, flame retardant.
• Applications: Pipes, cable insulation, window frames.

Polyvinyl Chloride (PVC) is a widely used synthetic plastic polymer known for its versatility, durability, and affordability. It comes in rigid and flexible forms, making it suitable for various applications.

Properties of PVC

• Durability: Resistant to wear, corrosion, and weathering.
• Chemical Resistance: Withstands acids, alkalis, and salts.
• Flame Retardant: Self-extinguishing properties.
• Versatile: Can be molded, extruded, or processed into various shapes.
• Cost-Effective: Economical to produce and maintain.

Applications of PVC

1. Construction Industry

• Pipes and Fittings: Used in plumbing, sewage, and drainage systems.
• Benefits: Corrosion-resistant, lightweight, and easy to install.
• Window Frames and Doors: Durable and energy-efficient.
• Roofing Membranes: Provides waterproofing and UV resistance.

2. Electrical Applications

• Cable Insulation: Protects wires and cables from moisture and chemicals.
• Benefits: Flame retardant and provides excellent electrical insulation.

3. Medical Applications

• Products: IV bags, tubing, and blood storage containers.
• Advantages: Biocompatible, sterilizable, and flexible.

4. Consumer Goods

• Products: Shower curtains, flooring, and wall coverings.
• Benefits: Water-resistant, durable, and easy to clean.

5. Packaging

• Uses: Blister packs and shrink wrap.
• Advantages: Protects products and extends shelf life.

6. Automotive Industry

• Components: Dashboard skins, door panels, and seat covers.
• Benefits: Durable, flexible, and resistant to wear.

7. Sporting Goods

• Products: Inflatable products, sports equipment, and yoga mats.
• Benefits: Lightweight, flexible, and durable.

Environmental Considerations

PVC is recyclable, and efforts are being made to improve its sustainability through recycling and reducing environmental impact.

Conclusion

Polyvinyl Chlorides combination of durability, versatility, and cost-effectiveness makes it essential across various industries. Its applications, from construction to medical devices, highlight its importance in modern manufacturing and everyday life.

Applications Overview

• Automotive Industry: Parts like bumpers, dashboards, and various interior components.
• Medical Industry: Syringes, tubing, and various medical devices.
• Consumer Goods: Toys, household items, and electronic housings.
• Packaging: Bottles, containers, and films.

Related Products

How TPE is Used to Make Products such as toys, tools or industrial applications: A Step-by-Step Process

Thermoplastic Elastomers (TPE) are widely used in toy manufacturing due to their flexibility, safety, and durability. Here’s a detailed step-by-step process of how TPE is used to make toys:

Step 1: Design and Prototyping

1. Concept Design: The process begins with the concept design of the toy. Designers create sketches or digital models of the toy, considering the desired features, size, and functionality.
2. 3D Modeling: Using CAD software, designers create a 3D model of the toy, which helps in visualizing the final product and making necessary adjustments.
3. Prototype Creation: A prototype is made using 3D printing or other prototyping techniques. This prototype is used for testing and refinement before mass production.

Step 2: Material Selection

1. Choosing the Right TPE: The appropriate type of TPE is selected based on the toys requirements. TPE comes in various grades with different levels of hardness, flexibility, and durability.
2. Color and Additives: Colorants and additives (e.g., UV stabilizers, flame retardants) are chosen to enhance the toys appearance and performance.

Step 3: Mold Creation

1. Mold Design: Engineers design molds based on the 3D model of the toy. The mold must be precise to ensure that the final product matches the design specifications.
2. Mold Fabrication: The mold is fabricated using materials like steel or aluminum. This step involves precision machining to create the cavities and cores that will shape the TPE into the desired toy form.

Step 4: TPE Injection Molding

1. Material Preparation: TPE pellets are fed into an injection molding machine. The machine heats the pellets until they melt into a fluid state.
2. Injection Process: The molten TPE is injected into the mold cavities under high pressure. The pressure ensures that the TPE fills all parts of the mold, capturing the fine details of the design.
3. Cooling and Solidification: Once the mold is filled, the TPE is allowed to cool and solidify. Cooling can be enhanced using water or air channels in the mold.
4. Ejection: After the TPE has cooled and solidified, the mold opens, and the toy is ejected. Ejector pins or plates may be used to push the toy out of the mold.

Step 5: Post-Processing

1. Trimming and Deburring: Excess material, known as flash, is trimmed from the toy. This step ensures that the edges are smooth and safe for children.
2. Surface Finishing: Additional surface treatments, such as painting, printing, or texturing, may be applied to enhance the toy’s appearance and feel.

Step 6: Quality Control

1. Inspection: Each toy undergoes thorough inspection to ensure it meets quality standards. This includes checking for defects, ensuring accurate dimensions, and verifying that colors and finishes are consistent.
2. Safety Testing: Toys are tested for safety, including checks for choking hazards, chemical composition, and mechanical strength, to comply with safety regulations.

Step 7: Assembly and Packaging

1. Assembly: If the toy consists of multiple parts, these parts are assembled. TPE components might be combined with other materials, such as plastics or metals.
2. Packaging: The final product is packaged. Packaging design is important for both protection during transport and attractive presentation to customers.

Step 8: Distribution

1. Warehousing: Packaged toys are stored in a warehouse, ready for distribution.
2. Shipping: Toys are shipped to retailers or directly to customers.

 Wondering what types or toys can FILIUM support you manufacturing? 

Types of Toys Produced Using TPE and Their Advantages

Thermoplastic Elastomers (TPE) are highly versatile materials used to manufacture a wide variety of toys. Here are some common types of toys produced using TPE along with their advantages:

Types of Toys Produced Using TPE

Soft Baby Toys

• Examples: Teething toys, soft rattles, squeezable toys.
• Advantages: Safe for infants, soft and flexible, easy to clean, non-toxic.

Action Figures and Dolls

• Examples: Bendable action figures, fashion dolls with flexible limbs.
• Advantages: Durable and flexible, realistic movement, resilient to rough play, easy to mold into intricate shapes.

Outdoor Toys

• Examples: Water toys, sports balls, flexible flying discs.
• Advantages: Weather-resistant, durable under various environmental conditions, soft enough to prevent injury.

Educational Toys

• Examples: Building blocks, sensory toys, tactile learning tools.
• Advantages: Enhances sensory development, flexible and safe for young children, bright colors and interesting textures.

Bath Toys

• Examples: Floating animals, bath squirters, waterproof dolls.
• Advantages: Water-resistant, mold-resistant, safe for use in water, easy to clean.

Plush Toys with TPE Components

• Examples: Stuffed animals with flexible noses or feet, soft dolls.
• Advantages: Adds tactile variety, flexible and safe, enhances durability.

Interactive Toys

• Examples: Squeeze toys that make noise, interactive pet toys.
• Advantages: Encourages interaction and engagement, durable and flexible, safe for repetitive use.

Stretchable and Squeezable Toys

• Examples: Stretchable figures, stress relief balls.
• Advantages: High elasticity, durable under repeated stretching and squeezing, provides a unique tactile experience.

Advantages of Using TPE in Toy Manufacturing

Safety

• TPE is non-toxic and free of harmful chemicals, making it safe for children.
• The soft and flexible nature of TPE reduces the risk of injury.

Durability

• TPE toys are resistant to tearing, stretching, and general wear and tear.
• They can withstand rough handling, making them ideal for active play.

Flexibility

• The elastic properties of TPE allow toys to be bent, twisted, and stretched without breaking.
• This flexibility makes TPE ideal for toys that require movement or deformability.

Ease of Molding

• TPE can be easily molded into complex shapes and intricate designs.
• This allows for the creation of detailed and varied toy designs.

Weather Resistance

• TPE is resistant to water, UV light, and extreme temperatures.
• Toys made from TPE can be used both indoors and outdoors without degrading.

Aesthetic Appeal

• TPE can be colored in a wide range of vibrant hues.
• It can also be textured to provide a pleasing tactile experience.

Recyclability

• TPE is recyclable, making it an environmentally friendly option for toy manufacturing.
• This aligns with growing consumer demand for sustainable products.