Alexei Volkov
Plastic injection moulding is an expensive process, with the cost of a single mould ranging from $3,000 to $100,000 or more. The price is determined by several factors, including the size of the plastic parts, the number of cavities, the basic structure, the type of material used, and the anticipated quantity. The cost of a prototype for injection moulding depends on the completeness of the design and the size of the part being designed. The price per unit decreases as the number of units produced increases.
| Characteristics | Values |
|---|---|
| Complexity of design | The more complex the design, the higher the cost |
| Size of the part | Larger parts are more expensive |
| Number of parts | The cost per unit decreases with higher quantities |
| Raw materials | The type of resin or plastic used affects the cost |
| Additional services | In-mold decorating and other services add to the cost |
| Prototype | The cost of a prototype depends on the completeness of the design and the size of the part |
| Machining process | The machining process is the most significant cost associated with injection molding |
| Production run | Longer production runs cost more |
| Setup costs | There may be setup costs for the molds |
| Mold maintenance | Maintenance and repair costs should be considered |
| Skilled labor | Training and skilled labor can add to the overall cost |
What You'll Learn
Cost depends on design complexity
The cost of custom plastic moulding depends on several factors, including the size, complexity, material, and anticipated quantity of the desired part. The more complex the design, the higher the cost, as more intricate details require additional time and expertise to execute.
The complexity of a design influences the cost of custom plastic moulding in several ways. Firstly, intricate designs often necessitate the use of high-strength steel or aluminium, which can increase expenses. The choice of material is crucial, as some resins are more expensive than others. For instance, engineering-grade resins, which can withstand extreme temperatures and friction, tend to be pricier than commodity-grade resins.
Additionally, complex designs may require the use of specialised equipment and machinery, such as cams, lifts, or core pins, which can further drive up costs. The number of cavities, or hollow sections, in a design also plays a role in determining the final cost. A higher number of cavities generally increases the price, as it requires more intricate tooling and a larger volume of raw material.
The desired quantity of the final product also impacts the cost of custom plastic moulding. Typically, creating a larger number of units results in a lower price per unit. This is because the initial setup and design costs are spread across a higher number of products, reducing the individual cost of each item.
It is worth noting that the cost of custom plastic moulding can vary significantly, ranging from a few thousand dollars to several hundred thousand dollars. The wide price range reflects the diverse nature of custom moulding projects, with each project presenting its own unique set of requirements and complexities. Therefore, it is essential to carefully consider the specific details of your project and consult with experts in the field to obtain accurate cost estimates.
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Raw materials and operation costs
The raw materials and operational costs of custom plastic moulding vary depending on several factors, including the size, complexity, material, and anticipated quantity of the mould.
Raw Materials
The cost of raw materials for custom plastic moulding depends on the type and amount of plastic resin used. Plastic resins can range from $0.90 to $2+ per pound, with engineering-grade plastics generally being more expensive than commodity-grade resins. The form in which the resin is bought also impacts the cost, as not all polypropylenes are moulding-ready, and it may be necessary to buy the resin in pellet form.
Operational Costs
Operational costs for custom plastic moulding can include the cost of the mould itself, as well as any design, prototyping, and setup costs. The price of a mould can vary widely depending on its size, complexity, and the number of cavities, with simple moulds starting at around $1,000 and large-scale moulds reaching several hundred thousand dollars.
Design costs can also add up, especially if a lot of design work is required before the mould can be created. For a small part with no design work, the mould cost may be around $2,000, while a small part with a complex design could cost between $20,000 and $40,000.
Prototyping costs depend on the completeness of the design and the size of the part, with a simple design for a small part potentially costing under $100, while a more complex design for the same-sized part could cost upwards of $2,000.
Other operational costs to consider include the injection time, cooling time, and any maintenance or repair costs associated with the mould. The injection time is the time it takes for the polymer to be injected into the mould, while the cooling time represents approximately 80% of the entire cycle time.
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Prototype moulds are cheaper
The cost of custom plastic moulding varies depending on the size, complexity, and design of the part. The price of a mould can range from $1,000 to $100,000 or more. However, prototype moulds are typically cheaper than production moulds.
Prototype moulds are created to test the design of a product before it enters mass production. They are usually made from less expensive materials, such as aluminium, silicon, or 3D-printed plastics, which are more affordable than the high-grade steel used in production moulds. The lower cost of materials and manufacturing gives designers more freedom to experiment with different designs and make rapid changes during the early stages of product development. This flexibility helps to prevent costly mistakes and defects that may not be discovered until after production has begun.
The cost of a prototype mould depends on the completeness of the design and the size of the part. A small part with a good design can be prototyped for under $100, while a small part with no design could cost around $2,000 for design work and under $100 for the prototype. 3D printing is a popular method for creating affordable and quick prototypes, especially for intricate geometries. However, 3D-printed prototypes may not always be suitable for large-scale moulding, as they are typically printed in smaller parts and then assembled.
In addition to the cost of the mould itself, it is important to consider the raw material, operation, and repair costs associated with custom plastic moulding. The price per unit can be low for plastic injection moulding, but the start-up costs for a large run can be expensive. The more units produced with a mould, the cheaper the price per unit becomes.
Overall, prototype moulds are a cost-effective way to test and refine a product design before committing to mass production. They provide designers and engineers with the flexibility to experiment and make changes without incurring significant costs. By using prototype moulds, businesses can reduce the risk of costly mistakes and improve the efficiency of the product development process.
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Large moulds cost more
The cost of custom plastic moulding varies depending on the scope and intricacy of the project. A small and simple single-cavity plastic injection mould usually costs between $1,000 and $5,000. Large moulds or complex moulds may cost as much as $80,000 or more. The price of a mould is just the beginning, as you also need to consider raw material, operation, and repair costs.
In addition, large moulds may require additional components such as cams, lifts, or core pins, which increase the cost. If the part has a higher volume, the mould would require more cavitation (parts moulded per cycle), which also adds to the cost. More cavitation means more parts handling equipment, such as conveyors, chutes, bowl feeders, and robots.
Furthermore, large moulds may require a multi-cavity tool if the demand for the part is very high, which also drives up the cost. Large moulds are also more difficult to produce, as they are subjected to thousands of pounds of pressure every cycle, so they must be made from durable materials that can withstand this pressure without deforming. This means that large moulds often have higher tooling costs and longer lead times.
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Custom mould geometry
The cost of custom plastic moulding varies depending on the size, complexity, material, and anticipated quantity of the desired product. The price of a simple mould typically falls between $1,000 and $10,000, while large-scale moulds can cost several hundred thousand dollars.
The first step in creating a custom mould is understanding the specific requirements of the product. This includes considering the size, dimensionality, and complexity of the product. For instance, a small part with a complex design can have a mould cost ranging from $20,000 to $40,000. On the other hand, a large part with a simple design can cost between $30,000 and $100,000. If the large part has no design, an additional $10,000 may be added for design work.
The complexity of the mould design also impacts the cost. More intricate designs, such as those with multiple cavities, are initially more expensive but can save time and money in longer production runs as they yield more pieces per cycle. Certain features in the product design may require additional components in the mould, such as cams, lifts, or core pins. Moreover, the choice of resin material is crucial, as it affects the durability, temperature resistance, and friction characteristics of the final product.
To ensure the success of the custom mould geometry, it is essential to work with experienced manufacturers who can provide tailored solutions. They can guide you through the entire process, from design to manufacturing, ensuring that your specific requirements are met. Additionally, it is beneficial to consider the availability of the chosen resin and explore multiple sources to secure your supply chain.
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Frequently asked questions
The cost of custom plastic moulding depends on several factors, including the size, complexity, and material of the part, as well as the anticipated quantity. Simple moulds can range from $3,000 to $6,000, while larger moulds can start at $25,000 and increase depending on the details involved. Large custom-designed parts can be even more expensive, with industrial plastic injection moulding machines costing over $200,000.
In addition to the size and complexity of the part, the cost of custom plastic moulding can be affected by the type of material used. Commodity-grade resins are typically less expensive than engineering-grade resins, which can withstand extreme temperatures and friction better. The production run time also affects the cost, with longer production runs requiring high-strength steel and increasing the overall cost.
The quantity produced can significantly impact the cost of custom plastic moulding. The more units created with the mould, the cheaper the price per unit becomes. This is because the start-up costs for a large run can be expensive, but the price per unit decreases as production continues.
Yes, there can be hidden costs associated with custom plastic moulding. In addition to the cost of the mould itself, there may be additional costs for design work, prototyping, and maintenance. The cost of the plastic weight can also vary, as it includes the plastic formed into parts and the hardened plastic left over in the mould.
