Within every vehicle, there are a variety of parts that have different materials, such as plastic. Many automotive parts have plastic components from injection molding. These offer numerous benefits to drivers and their vehicles. Read on to learn the benefits of injection molding automotive parts and why producing great vehicles is necessary.

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Affordable Parts

Most parts made of metal cost more than plastic parts. The metals needed to make certain parts, such as the rims and chassis of a car, are limited resources, and most suppliers price them higher because of their value or rarity.

Plastic injection molding can construct many parts without this limitation, making it more accessible and affordable. These affordable parts put less stress on car companies that need access to parts that require replacement, such as the knobs of a stereo or the handles of a car door.

Faster Production

Production is an essential aspect of manufacturing that needs to remain as high as possible to meet demand. The automotive industry's reliability comes from its ability to mass-produce vehicles and their parts. Injection molding benefits this industry by offering a fast turnaround for requests.

An injection molded design is easy to mass produce quickly thanks to the swiftness of the machinery and the fast process of molding the resin. Vehicle parts will have no shortage of available parts with the benefit of quick production within a demanding industry.

Durability

Although people see vehicles’ exteriors as the most durable parts because of their metal composition, they still have the potential to rust and corrode over time. Injection-molded parts of an automotive vehicle are some of the most durable pieces in the structure. Plastic lasts significantly longer than metal and maintains its shape and structure for decades.

The variety of options of polymers to use in the process is a great benefit of injection molding automotive parts. And each option has various advantageous characteristics that ensure the parts remain in good shape for years. Things like the steering wheel maintain their integrity despite constant handling and pressure from people's grips because of the injection molding.

Flexible Design

As vehicles continue to push the boundaries of functionality and control for the driver, automotive parts may have different designs that require flexible manufacturing. Thanks to its flexibility, injection molding is the best process for designing new or innovative designs.

This is thanks to the variety of molds to choose from. Plastic injection molding parts with detailed designs or nuanced shapes are easier to make, and you won't lose the efficiency in production regardless of how unique the design is.

Injection molding is a valuable process for many industries, especially automotive. Use plastic injection molding and reap the benefits of its fast-paced manufacturing for your automotive needs and drive toward your business's goals.

5 Advantages of Using Injection Molded Parts

Increasing regulation and interest in lowering carbon emissions has spilled into the realm of automakers, who are trying to reduce gross vehicle weight. This in turn has resulted in many automakers switching to plastic injection molded parts where they can.

What are some of the advantages of using plastic over metals? Why injection molded plastic instead of other machining methods like 3D printing or subtractive processes?

We’re going to cover why injection molding is your solution to lower gross vehicle weight and a more sustainable future. Keep reading to see how plastic injection molding can do that and more.

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1. Low Scrap Rates

Compared to traditional subtractive processes like CNC machining a sheet or billet of plastic, injection molding produces much lower scrap rates. While 3D printing has still lower scrap rates, it’s more suited to low quantity part orders.

The main waste of injection molding comes from runners, sprues, gates, and any “flash,” or overflow, areas. What do you do with that waste? More on that next.

2. Recyclable

There’s a benefit to thermoplastic waste that you don’t have with metal scrap, as well. It can be remelted, reformed, and recycled to complete an in-house recycling loop.

A CNC machining shop generally isn’t going to melt down their own metal and create new billets. Thermoset materials like epoxy resin, once cured, will burn rather than melt when reheated.

Thermoplastic, on the other hand, will handle melt cycles better, which is the basis for injection molding. Even a CNC shop that is cutting a thermoplastic piece probably wouldn’t recycle their waste into a new billet, instead opting to send it to a recycler.

3. Economy of Scale After Initial Costs

It does take considerable time and cost on the initial prototyping and tooling phase, requiring 3D printing or CNC machining for the prototype piece and mold. Although, the economy of scale and lack of labor costs more than makeup for the initial cost of making the prototype and mold.

If you can mold eight parts per cycle and get two cycles per minute, you get 7,680 parts per 8-hour shift from a single mold. With only four molds, you bring the production time of 1 million pieces down to about one month of production.

That being done with minimal labor, compared to CNC, and the mold is ready for millions of cycles more. Most cycle times for a simple product are within 1-5 seconds, much lower than our example.

4. Reproducible Quality

While CNC machining produces amazing quality, there is more variability in CNC machining or 3D printing to injection molding. When it comes to surface quality, injection molding beats out 3D printing.

The simple matter of the quality is that as long as the mold is good, you’ll get veritable clones of a product with no variation during the production lifetime of the project.

5. Design Flexibility

With custom injection molding you can have an incredible variety of materials and design features. A part can have a rubberized and textured side with a rigid backing. You can also have different colors for different options—for cars, that means variation on interiors and textures.

The Best Choice: Injection Molded Parts

It’s clear that for global size projects, you need a global leader in injection molded parts. Mayco International has over a million square feet of manufacturing space with more than 5,000 employees. With headquarters in Sterling Heights, Michigan, Mayco International is a Tier 1 supplier in 47 plants across seven countries, worldwide.

Contact us to discuss your requirements of Plastic Injection Molds. Our experienced sales team can help you identify the options that best suit your needs.