Injection molding is a versatile and cost-effective option for producing large volumes of components with minimal variance. Large parts, in particular, require specialized equipment, tooling, and expertise to mold due to their large dimensions and level of detail. Large-part injection molding is a type of high-pressure, thin-wall injection molding method that produces large plastic parts for automobiles, medical devices, industrial equipment, and more. Experienced injection molders can produce large-tonnage injection molded goods with fine detailing and intricate shapes without the risk of air bubbles, weak points, or inconsistencies.
Learn more about how large-part injection molding is used in automotive, industrial, and medical device manufacturing.
Automotive
The biggest factors shaping how manufacturers build modern cars are energy efficiency and aerodynamics. This means making lighter cars that consume less fuel. Large-part injection molding meets these needs because manufacturers can replace components that otherwise would be metal with injection-molded plastics. Common metal components that can be replaced with plastics include:
- Spoilers
- Bearings
- Fan blades
- Manifolds
- Latches
- Fuel tank caps
Injection molding is already making cars lighter and more efficient by replacing small metal components with plastic ones, so being able to injection mold much larger components pushes the possibilities even further. Injection molders often use the following types of plastics as replacements for metal components:
- Acetal
- Acrylic
- Acrylonitrile butadiene styrene (ABS)
- Nylon
- Polycarbonate
- Polypropylene
Manufacturers also have access to a wide range of colorized specialty plastic compounds that don’t require painting, tinting, powder coating, or other finishing stages later in the production process. Furthermore, techniques like overmolding can eliminate the need for additional clips or fasteners to join separate components. Removing these extra steps reduces production costs and timelines.
Industrial
Large-part injection molding also benefits industrial machinery fabrication. Conveyor systems, automated processing lines, and distribution systems all require large, intricate components that are heavy and expensive to build from metals. Through large-part injection molding, manufacturers can replace components such as housings, fan turbines, enclosures, panels, and more with long-lasting, lightweight plastics.
Large-tonnage injection molding processes can create very large components out of specialty plastics, from UV-resistant thermoplastics to food-safe materials for use in food and beverage manufacturing. As the technology for large-part injection molding continues to advance, industrial equipment will continue to benefit from the functionality, sustainability, and innovation of new materials and components.
Medical
Injection molding is already creating various components throughout the medical industry, including those for wearables, handheld medical devices, and small tools. However, with plastic injection molding large parts, medical providers and patients benefit from an even wider array of medical goods and assemblies.
The ability to injection mold large, intricate components means medical equipment manufacturers can build better products that meet strict requirements for reliability and hygiene. Examples of these medical devices include:
- Patient monitors
- Diagnostic equipment
- Hospital beds
- MRI and radiation therapy equipment
- Imaging systems
Plastics are lightweight and long-lasting, so healthcare staff can easily move portable equipment. Medical-grade plastics withstand frequent cleaning, sterilization, and exposure to chemicals or biological fluids. The main types of large-part injection molding used in the medical industry are insert molding, overmolding, and molding with sliders.
Large-Part Injection Molding From Lerner Molded Plastics
Lerner Molded Plastics is a leading provider of high-quality plastic goods through custom injection molding services, including overmolding and plastic injection molding large parts, with shot sizes up to 600 ounces. As an ISO 9001:2015 certified manufacturer, we’re continuously innovating our capabilities and quality management systems to give our customers the best injection molded components for their projects.
As a premier plastics manufacturer in Ohio, Lerner Molded Plastics operates a manufacturing center with molding equipment that can generate up to 3,000 tons of force in molds with up to 64 cavities. Our molding capabilities include custom coloring options, blow molding, large-part rotational molding, tooling design and build services, and thermoforming services.
Contact us today to learn more about our capabilities, or request a quote to start your large-part injection molding project.