Injection moulding near me | cost of Injection moulding

Injection Moulding Near Me | Overview of Injection Mould Cost

The first thing you need to know is: what companies are offering injection moulding near me?

Then you can contact them and delve into the costs associated with your project.

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Determining the injection mould cost is not a straightforward task as it is subject to various factors. Considering all the variables involved is crucial in evaluating the overall cost of the injection mould. One must carefully weigh the cost of the mould against the number of parts being manufactured. Producing higher quantities of parts will result in a lower per-piece cost, as the total injection mould cost can be distributed over hundreds or thousands of pieces. Despite the initial expense, injection moulding remains the quickest and most cost-effective method for producing large quantities of plastic parts.

How to Calculate Injection Moulding Cost. 

The cost of plastic injection mould tooling largely relies on the machining of the injection mould. Several factors come into play when determining the cost. The complexity of the mould is the key element in the cost of the tooling, the size of the mould is also a significant factor in its cost. Larger and more intricate moulds will naturally be more costly compared to smaller and simpler moulds. Additionally, the type of mould influences its price. Prototype injection moulds typically cost less than moulds used for production runs. On the other hand, moulds intended for long production runs will incur higher expenses. To withstand repeated use during extended production, these moulds need to be constructed from strong, high-strength, fully hardened steel, steel such as P20 or anti-corrosion stainless steel. How the part is going to be fed is an often-under-considered factor as well.  This could be from a myriad of different cold feed options or if the need arises a hot feed may be necessary to suit your application. Gate vestige, gate size and plastic runner waste factor need to be considered so we understand what type of runner and feed is ideally suited to the product.

The number of injection cavities built into the mould is the final factor to consider. High-production moulds often have multiple, identical injection cavities, known as multi-cavity moulds. Meanwhile, family moulds feature two or more similar cavities that may not be identical. An example is moulds producing the right and left sides of a part that snap together. These moulds consist of multiple cavities that produce the same part or related parts in a single press, reducing the frequency of opening and closing the mould while enhancing production efficiency. 

The following are some of the questions that will need answering to enable the best price solution for your project: –

  • How many products do you require per batch and per annum? 
  • Do you know what material you may want to use, if not can you explain the function and ergonomic requirements of the product and we can offer advice?
  • Part colour, does this need to be a specific RAL colour, or colour-matched? 
  • Expected total life for the product? 
  • Do you have any specific tooling specification requirements?  
  • What is the expected surface finish for the part?  
  • Is the part design open for change to help us to offer you a cheaper longer lasting, better overall solution for the mould tooling?  
  • Do the parts need to comply with any regulations, such as fire-retardant UV degradation? 
  • Are there any other factors that may influence the parts going forward that may need to be considered? 
  • Do you require prototypes? 
  • Do you require design advice and help?  

 

To find out more about injection moulding services please contact Benn Simms, benn.simms@ledwellplastics.com Managing Director of Ledwell.

Injection Moulding

 

Injection Moulding Plastics | The Importance of Testing and Validation in Injection Moulding Plastics

Testing and Validation of injection moulding plastics

Introduction

Injection moulding plastics is a widely used manufacturing process for creating plastic parts and products. To ensure the success of a project, it is crucial to implement thorough testing and validation methods. This article will delve into the significance of testing and validation in injection moulding plastics, exploring the various standards, regulations, tools, and processes involved. By understanding the importance of these practices, manufacturers can achieve greater efficiency, product integrity, and cost-effectiveness in their operations.

Understanding Testing and Validation

Testing and validation in injection moulding plastics involve the systematic evaluation of the manufacturing process and the final products to ensure they meet the required quality and performance standards. These processes help identify any potential issues, defects, or deviations from specifications, allowing manufacturers to make necessary adjustments and improvements. By validating the manufacturing process, manufacturers can create a stable and reliable production system that consistently delivers high-quality products.

Standards and Regulations

Standards and regulations play a crucial role in the testing and validation of plastic injection moulded products. Regulatory bodies vary from country to country. In the USA the FDA (U.S. Food and Drug Administration) and in the EU, the European Commission, have specific guidelines and requirements that manufacturers must adhere to. These guidelines ensure that critical aspects of the manufacturing operation are validated throughout the product lifecycle, including any changes that may impact product quality. Compliance with these standards is essential for gaining regulatory approval and maintaining product safety.

The Process Design Phase

The process design phase is an integral part of testing and validation in plastic injection moulding. During this phase, manufacturers evaluate the sizing and calibration of the equipment, such as the injection moulding machine. Proper calibration and equipment selection are essential to ensure the manufacturing process is optimised and capable of producing high-quality products. Manufacturers must carefully consider factors like shot size, tonnage, and machine settings to achieve the desired outcomes.

Process Qualification and Dimensional Studies

Process qualification involves establishing a range of process parameters that ensure the stability and consistency of the injection moulding process. Statistical and dimensional studies are conducted to identify any deviations or variations in the process that may impact the quality of the final product. This phase aims to validate that the variations are within acceptable limits and do not adversely affect the finished product. By conducting these studies, manufacturers can ensure that their products consistently meet the required specifications.

Continued Process Verification

Continued process verification focuses on demonstrating the long-term stability and consistency of the injection moulding process. Manufacturers simulate different production runs using the same equipment and processes to ensure repeatability and reliability. This phase is crucial for assessing the ongoing performance of the manufacturing process and identifying any potential issues or deviations. Regular monitoring and documentation of the injection moulding process are necessary to maintain compliance with ISO 13485 standards and other regulatory requirements.

Collaboration and Communication

Effective collaboration and communication between manufacturers, suppliers, and customers are essential for successful testing and validation in plastic injection moulding. Clear expectations and requirements must be established from the outset to ensure all parties are aligned. Manufacturers should work closely with their customers to understand the critical factors and performance criteria that need to be validated. By fostering open communication, manufacturers can address any concerns or challenges that may arise during the testing and validation process.

Tools and Technology

The use of advanced tools and technology greatly facilitates testing and validation in plastic injection moulding. Simulation software allows manufacturers to predict and optimise the moulding process before actual production. This technology helps identify potential issues, such as part warping or inadequate fill, enabling manufacturers to make necessary design modifications. Additionally, robotics and process control systems enhance the precision and efficiency of the moulding process, ensuring consistent quality and reducing the risk of defects.

Risk Management and Product Integrity

Risk management is a crucial aspect of testing and validation in plastic injection moulding. Manufacturers must identify and mitigate potential risks throughout the manufacturing process to ensure product integrity. This includes addressing changes in pressure, temperature, flow rate, and cooling rates, which may require re-validation exercises. By proactively managing risks, manufacturers can minimise the occurrence of defects, product recalls, and costly rework. It is essential to establish a robust risk management framework that encompasses all stages of the injection moulding process.

Benefits of Testing and Validation

Thorough testing and validation in plastic injection moulding offer numerous benefits to manufacturers. By implementing these processes, manufacturers can achieve greater levels of customer satisfaction, lower production costs, and increased profitability. Testing and validation help identify and resolve potential issues early in the manufacturing process, reducing the risk of delays and costly rework. Additionally, these processes contribute to the overall efficiency and reliability of the production system, ensuring the consistent delivery of high-quality products.

Conclusion

Testing and validation are critical components of the plastic injection moulding process. By following established standards and regulations, collaborating effectively, leveraging advanced tools and technology, and managing risks, manufacturers can ensure the quality and integrity of their products. Thorough testing and validation not only lead to regulatory compliance but also contribute to improved efficiency, reduced costs, and increased customer satisfaction. By prioritising testing and validation, manufacturers can achieve long-term success in the highly competitive world of plastic injection moulding.

To find out more about plastic injection moulding please contact Benn Simms benn.simms@ledwellplastics.com Managing Director of Ledwell

Injection Moulding

Injection moulding services company Ledwell goes for growth

Injection moulding services company Ledwell purchases new factory to enable growth

 

plastic injection moulding company

As Ledwell’s business continues to grow, we are excited to announce that we have acquired a new factory site to better serve you. This expansion will help us to meet the increasing demand for our injection moulding services and allow us to provide even better quality and faster turnaround times. Our new factory site will allow us to increase our production capacity and improve our efficiency. We are proud to be able to continue to innovate and expand, and we look forward to the new opportunities this will bring for our customers.

Our goal has always been to provide high-quality products and services to our customers, and with the new factory site, we can now do so even more efficiently and effectively. This expansion will allow us to streamline our operations, which will ultimately benefit our customers. We are thrilled to embark on this new journey and look forward to the exciting opportunities that lie ahead.

Our previous site was operating at maximum capacity and we were finding it increasingly difficult to keep up with demand. Commenting on the new site, Benn Simms, Managing Director of Ledwell said “We found ourselves a victim of our own success.  Our business grew substantially despite the challenging economic climate.  It was soon realised that space was paramount to the continued success of Ledwell Plastics. After evaluating several properties near to our existing factories a suitable facility was found.  We now have an efficient storage facility that is meeting our current needs and gives us capacity in line with our goals and strategy. I’m incredibly proud of our team and their achievements to adapt and continue to build on our 55 years”.

To find out more about Ledwell’s injection moulding services please contact Benn Simms benn.simms@ledwellplastics.com Managing Director of Ledwell.

 

Plastic Moulding Company Ledwell invests in In-Touch | Cutting-Edge IT Production Systems

Ledwell | Plastic Moulders Make Major Investment in Injection Moulding Machines & Robots

Ledwell | Plastic Moulders Make Major Investment in Injection Moulding Machines & Robots

To maintain our growth, offer clients more scope and improve production efficiencies plastic moulders are investing in new injection moulding machines and robots.

Benn Simms, Managing Director of Ledwell said, “We are a leading injection moulding company in the UK.  To maintain our position and offer clients the solutions they need, we are continually investing in new technologies”.

How Plastic Moulders are Improving Production Efficiency in Injection Moulding with Robotic Automation

In today’s fast-paced injection moulding industry, companies are constantly seeking ways to improve production efficiency and gain a competitive edge. With the advent of robotic automation, injection moulding companies can now streamline their operations, enhance product quality, and increase overall productivity. In this article, we will explore the various ways in which robots can and have improved the production efficiency of injection moulding, at Ledwell, along with the benefits they bring to the table.

The Rise of Robotics in Injection Moulding

The demand for more flexible solutions in the plastics industry has led to the extensive use of industrial robots in injection moulding operations. These robots can automate the entire injection moulding process, from loading plastic parts into the machine to placing the finished products onto a conveyor belt. By replacing human-operated injection moulding with robots, companies can ensure the consistent production of high-quality products that are accurately formed.

Advantages of Robotic Automation

The utilisation of robotics in injection moulding offers several advantages for manufacturers. Firstly, it provides them with a competitive advantage by increasing both productivity and the quality of the produced parts. Robots can work faster and more efficiently than humans, leading to higher output and reduced cycle times. Additionally, robots can perform highly repetitive tasks 24/7 without the need for breaks or rest, maximising the utilisation of injection moulding equipment and increasing overall efficiency.

Another significant advantage of robotic automation is the improvement in product quality. Robots can perform precise and repeatable tasks, ensuring consistent quality and reducing the risk of errors or defects. They can also handle parts in a controlled and consistent manner, reducing the risk of contamination and improving the overall quality of the final product. By incorporating robots into the injection moulding process, manufacturers can reduce waste, minimise the need for rework or scrap, and deliver products that meet the required specifications.

Application of Robotics in Injection Moulding

Robots have a wide range of applications in different stages of the injection moulding process. One common application is machine tending, where robots are used to unload finished parts from the injection moulding machine and deliver them to downstream processes such as packaging. By automating this task, manufacturers can improve product consistency, reduce the risk of injuries to labourers, and increase production capacity.

Another important application is insert moulding, which involves enclosing inserts such as pins or threaded rods in moulded plastic. Robots, such as SCARA robots, can add inserts to mouldings and load them into machines to continue the process. They can also work in collaboration with pick-and-place robots to complete the manufacturing process.

Automation can also be applied to over-moulding, where a moulded object is removed from one injection moulding machine and placed into another with the help of a robot. This automated process ensures a more efficient and accurate arrangement of parts, reducing labour and assembly expenses while ensuring the quality and integrity of the final product.

In-mould labelling is another popular application for automation in injection moulding. Robots can feed pre-printed labels or decorated film directly into the open plastic injection mould, ensuring precise and stable positioning of labels. This process enhances the visual appeal of the final product and eliminates the need for secondary processing or shipping parts to and from warehouses.

Post-processing tasks, such as inspection, testing, and trimming of plastic moulded parts, can also be automated using robots. Robotic trimming cells provide superior repeatability compared to manual trimming, resulting in higher precision, accuracy, and cycle times. Robots can minimise waste and improve production efficiency by reducing errors and defects.

The Future of Robotic Technology in Injection Moulding

The future of robotic technology in injection moulding looks promising, with ongoing advancements aimed at simplifying operations and maximising overall equipment effectiveness. Companies like Sepro Group are breaking new ground in the area of robot and automation control. Their work focuses on simplifying robot programming with the use of artificial intelligence (AI) and creating highly integrated control systems that communicate with all equipment in a production cell.

Plastic moulders can overcome the technical complexities associated with robot programming by implementing “no-code” programming and AI-driven robot controllers. This enables easier retrofitting of code or hardware to evolving business and market needs, making robotic automation more accessible and user-friendly. As a result, even relatively new employees with limited training can set up basic moulding processes, further reducing the need for skilled technicians.

In conclusion, robotic automation offers immense potential for improving production efficiency in injection moulding. Manufacturers can increase productivity, enhance product quality, and reduce costs by utilising robots in various stages of the process. Robots’ flexibility, precision, and efficiency contribute to the overall competitiveness of injection moulding companies. As technology advances, the future of robotic automation in injection moulding looks promising, paving the way for further innovations and improvements in the industry.

 

Injection Moulded Parts | Advantages and Disadvantages

Plastic Injection Moulding Near Me : Tips on Maintaining the Quality of High Gloss Injection Moulded Parts.

Plastic Injection Moulding Near Me: Tips for maintaining a high gloss finish. There is an art to keeping your high gloss in top condition

Plastic Injection Moulding Near Me | High gloss injection moulded parts are becoming increasingly popular for their sleek and modern look. However, maintaining the quality and shine of these parts can be a daunting task. Scratches, dust, and other damage can quickly diminish their appearance. In this article, we will provide you with tips and tricks on how to maintain the quality of these parts so that they stay looking as good as new for years to come. From cleaning and polishing techniques to proper storage and handling, you’ll learn everything you need to know to keep them looking their best.

 

1.0 What are high gloss injection moulded parts?

High gloss injection moulded parts are a popular choice for manufacturing a variety of products today. These parts are made by injecting molten plastic into a mould and then allowing it to cool and solidify into a specific shape and size. The result is a product that has a smooth, glossy finish that is both durable and aesthetically pleasing to the eye. These parts are used in everything from automotive interiors to consumer electronics to medical devices. They are particularly popular in industries where appearance and durability are crucial, such as the automotive and home appliance industries. High gloss parts are known for their excellent quality and have become widely used for manufacturing products that require a strong and attractive finish.

2.0 How to clean and polish high gloss injection moulded parts

High gloss parts and products are chosen by designers as they add a sleek and polished look. However, maintaining the quality of these parts requires a little extra effort and care. When it comes to cleaning and polishing these parts, there are a few things to keep in mind. First, you should always use mild soap and lukewarm water to clean the surface. Avoid using harsh chemicals or scrubbing brushes as they can scratch or damage the surface. Once you have thoroughly cleaned the surface, it’s time to polish it. There are several ways to polish the parts, but one of the most effective methods is to use a high-quality polish that is specifically designed for plastic surfaces. Apply the polish to a soft cloth and gently buff the surface in a circular motion. This will help to remove any minor scratches or blemishes and leave the surface looking shiny and new. It is important to remember that regular maintenance is key to keeping them looking their best. With a little extra care and attention, you can ensure that your products always shine on.

3.0 Proper storage and handling of high gloss injection moulded parts

Proper storage and handling of high gloss parts and products is essential to maintain their quality. It’s crucial to ensure that these parts are stored in a clean, dry, and dust-free environment. Any dirt or dust particles can scratch the surface of the parts, which can mar their high gloss finish. You should also avoid touching the high gloss surface directly with any sharp or abrasive objects as this can cause scratches or damage to the finish. When it comes to storing, you should use protective packaging or covers to avoid any contact with other objects that may scratch or damage the surface. If the parts are large and require stacking, you should use protective materials such as foam to prevent any damage from the pressure of the parts’ weight. It’s also important to store high gloss parts away from heat sources or direct sunlight. The heat can cause the parts to warp, and the sunlight can cause fading or discolouration over time. By following these proper storage and handling procedures, you can help maintain the quality and high gloss finish of your injection moulded parts, ensuring they look and perform their best for years to come.

4.0 Conclusion.

Maintaining the quality of your parts and products requires consistent effort and attention to detail. However, it is well worth the investment, as these parts can add a beautiful and polished look to any product. By using the right cleaning tools and techniques, avoiding harsh chemicals, and protecting the parts from scratches and damage, you can keep your products and parts looking like new for years to come. Whether you are a manufacturer or a consumer, these tips can help you get the most out of your parts and products. With a little bit of care and attention, you can keep your parts looking shiny and new for a long time.

 

For more information on the storage and upkeep of your high gloss injection moulded component and products, please contact Benn Simms,  benn.simms@ledwellplastics.com Managing Director of Ledwell – Plastic Injection Moulding Near Me

Injection Moulding

Ledwell Expands Quality Control | Meet Paige

Quality Control in the Field of Injection Moulding: An In-Depth Guide

**Paige Otter, Ledwell’s Quality Control Supervisor

Injection moulding, a cornerstone manufacturing process, has been the backbone of the plastic industry for decades. It’s a complex procedure that requires precision, expertise, and strict quality control measures. This post delves into the quality control aspect of injection moulding, highlighting its importance, the procedures involved, and the benefits it offers.

The Art of Injection Moulding

Before diving into quality control, let’s understand the process of injection moulding. It’s a technique where molten plastic or composites are forced into a mould to create a part, a product or component. There is a wide range of different plastics to choose from as well as composites and biodegradable materials. The process begins with the material being heated until it becomes molten. It’s then injected into a mould under pressure, cooled to solidify, and eventually removed from the mould. The result is a solid part fashioned and engineered from your chosen material.

Injection moulding technology came into existence in the early 1870s, initially used to manufacture billiard balls. Fast forward to today, and injection moulding has become a versatile method to create a plethora of products – from drink tumblers and automotive parts to musical instruments and medical devices.

The Vital Role of Quality Control in Injection Moulding

In the world of injection moulding, quality control is crucial. It’s a systematic process that ensures the final products meet the set specifications and consumer expectations. Several factors, including dimensional stability, colour, gloss, and moulding defects, define how well the product aligns with the intended design and overall quality.

Quality control is not just a term used to boost brand image or a buzzword thrown around casually. It’s a rigorous process that involves meticulous planning, design, development, assembly, production, and packaging. Quality control measures are integral to the success of a business, reducing production costs and boosting customer satisfaction.

Dimensional Stability and Quality

Dimensional stability is an important aspect of quality control. If the product is an individual piece that doesn’t connect to anything, the dimensions might not matter. However, for components that fit together to form an assembled product, having the correct dimensions is crucial.

Each component must conform to specific dimensions to fit with other parts correctly. This includes being neither too large nor too small and maintaining the right shape to fit, perfectly with other components. If the components don’t fit together, the entire assembly might not function as intended, resulting in halted manufacturing lines or dissatisfied customers.

The Impact of Colour in Injection Moulding Quality Control

Colour is another critical factor that can affect the overall quality of the product. Changing process parameters, such as increasing or decreasing temperature and pressure, can affect the end colour of the product. There are different ways to colour the plastic, including pre-coloured plastic from a plastics manufacturer or a blended plastic created at the moulding factory.

Colour harmony is crucial to ensure each component meets the specification, meaning each part aligns with the intended colour within a few shades. It’s important to show uniformity and consistency of colour between all components, meeting the design intent.

The Role of Gloss in Product Quality

Gloss, though a small detail, can significantly influence the perceived quality of the product. The right gloss level can enhance your product’s visual appeal, influencing your consumer’s perception. The process parameters during moulding can influence gloss to a certain degree. For instance, high temperature may increase gloss, while the time in the mould could decrease the gloss level of your product.

Common Moulding Defects and Quality Control

Moulding defects can affect the quality of your product. The five most common defects that may occur include flow/weld lines, sink marks, short shots, burn marks, and flashing. Each of these defects can compromise the overall quality of the product, deterring customers from purchasing it.

However, not all defects warrant discarding the product. For instance, some defects might be acceptable on an internal component that isn’t visible after assembly. The product specification should outline if a defect is acceptable, its acceptable location, and the degree of defectiveness allowed.

Benefits of Quality Control in Injection Moulding

Quality control in injection moulding comes with numerous benefits. It encourages a quality-conscious approach among the workers, leading to higher product quality. It also reduces production costs by minimising waste and inefficiencies. Companies can ensure the utilisation of resources, improve employee morale, and satisfy customers by maintaining stringent quality control measures. Additionally, quality control helps identify and fix problems early, reducing returns and failures.

Quality Control Trends: AI and Advanced Quality Assurance Tools

Quality control in injection moulding has seen significant advancements with the emergence of artificial intelligence (AI) and advanced quality assurance tools. AI enables complex and reliable quality control systems, ensuring consistency in mass production. The integration of AI with quality control systems allows automatic adjustments to the moulding cycle, improving the overall production process.

In addition to AI, advanced quality assurance tools like IdentiPol QA2 have revolutionised quality control in injection moulding. It enables efficient quality assurance tests, ensuring consistency and quality across the production line. It’s a user-friendly tool that grades plastics based on a pass or fail basis, bridging the gap between simple testing and complex lab analysis.

To find out more about Ledwell’s quality control procedures please contact Paige Otter paige.otter@ledwellplastics.com Ledwell’s quality control supervisor.

Ledwell Plastics excels at injection mould design, toolmaking, plastics injection moulding, assembly, and just in time production.  We offer a turnkey solution that can organise a new product launch from concept to consumer.  We have a complete turn-key solution to bring your product to market, and we are ISO9001:2015 certified

Peter Has Taken on Technical Sales and Marketing at Ledwell

New Technical Sales and Marketing Manager at Ledwell

Ledwell Plastics are delighted to announce that Peter Wilkinson has joined the team as Sales and Marketing Manager.

 

Marketing Manager at Ledwell | Peter brings with him a great depth and breadth of experience, built on over 40 years of marketing technical and engineering products. His knowledge across the board will benefit our team at this exciting time of growth. Peter is here to help Ledwell’s clients with technical sales enquiries.  From a mould making, casting and injection moulding background, Peter will ensure the best solutions are presented for your needs.

Benn Simms, Managing Director, commented; “I am looking forward to working with Peter and I am confident that the broad experience that he brings to the role will help to accelerate Ledwell to the next stage of our growth, whilst ensuring that we further develop strong systems and customer satisfaction levels”.

Peter added; “I’m delighted to join Ledwell at this exciting time of development across the business. I’m looking forward to a bright future with the company and working collaboratively with all our teams internally.”

To contact Peter for technical or sales enquiries please email peter.wilkinson@ledwellplastics.com or call Peter on 07930330125

 

READ OUR REVIEWS

You don’t need to take our word for it. Here’s what our customers have to say.

  • We have worked with Ledwell for many years, always a great service!

    Charlotte Smith Avatar Charlotte Smith

    Great company! We have been working with Ledwell for many years and have always found them to be friendly and helpful. Matt and Shirley in particular provide an excellent service.

    Peter Smith Avatar Peter Smith

    Been here for years, something must be right.

    adie seare Avatar adie seare

    We are only a small customer to them but always feel valued, would not hesitate to recommend them.

    Andy McCaughan Avatar Andy McCaughan
  • Great injection moulding company! High-quality services and friendly and helpful staff. Highly recommended!

    Aditi Dharmesh Avatar Aditi Dharmesh

    Great people, true British manufacturing thoroughbred

    Peter Wilkinson Avatar Peter Wilkinson

    Great place to work with likeminded brilliant people.

    Benn Simms Avatar Benn Simms

    Great blokes on Goods in.

    STEPHEN NIXON Avatar STEPHEN NIXON
  • Manufacturers of High Quality Injection Moulded Plastic Products #InjectionMolding #Toolmakers #Moulders

    Balu Nandigam Avatar Balu Nandigam

    10/10 would go again

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