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Plastic Injection Moulding

Plastic Injection Moulding is a process allowing multiple components to be produced to the exact same design and specification, quickly, accurately and relatively cheaply. If you have a requirement for a strong product, that is available in small or large quantities – Injection Moulding is one of the most cost effective production methods.

The plastic material begins in granules; this is heated and melted into a liquid form. This is then injected into the mould under high pressure, filling all cavities, creating a copy of the shape within the mould. The moulding is then cooled, until the impression turns solid, at which point the two halves of the mould separate and eject the finished item.

Here at DLS we have many years of experience in injection moulding, and all our mould room staff are highly trained. The injection moulding machine operatives are also experts in picking the best material for your product and setting up the optimum conditions to make the most of each material’s characteristics. Below is a selection of the materials that we mould in house:
  • Polypropylene (PP)
  • Nylon PA66
  • High Density Polyethylene (HDPE)
  • Lucofin ®
  • Homopolypropylene
  • Glass Filled Nylon PA6
  • Purell Medical Approved Homopolypropylene (Gamma Stabilised)
  • Lifocork ®
  • Talc Filled Polypropylene
  • Luran
  • Q-Resin
  • Plating Grade ABS
  • Glass Filled Polypropylene
  • Styrene's
  • Polycarbonates
  • Bayblend ® ABS/Polycarbonate Plating Grade Blend
  • ABS
  • Thermoplastic Elastomors (TPE)
  • Acrylics
  • Nylon PA6
  • Low Density Polyethylene (LDPE)
  • Coolpoly Polyphenylene Sulfide (PFS)

We can also offer additives in materials to cater for U.V protection. If you cannot see the material that you require, or are unsure which material would best suit your requirements please contact us. We are happy to advise on the correct material for your product and source and mould in new materials if required. We stock a large selection of standard colour additives, but we can also offer a colour matching service.

Small batch quantities or large production runs can all be catered for, allowing for maximum flexibility.

Gas Assist Injection Moulding:

Gas assist injection moulding is a process where nitrogen is injected into the melt stream to form a bubble and core out the part, leaving a hollow void in a predetermined position within the moulding.

The key advantages of gas assist injection moulding are:

Strength – Tubular structures within the mouldings provide strength and rigidity. For example our range of gas injected Grab Handles are Pull Tested and able to withstand 125kg of weight hung from them without breaking, despite weighing on average under 150g.

Weight Reduction – If your product incorporates large sections of moulding, creating a hollow core in those sections allows for a lower material content; this in turn greatly reduces the final component weight.

Design Flexibility –The pressure of the injected gas reduces the contracting effect when the plastic cools and reduces flow and sink marks, meaning customers do not have to compromise on surface finish and moulding aesthetics. This helps if your component design incorporates large surface areas or thicker wall sections. Cost Reduction – Having a hollow core in each component also allows for less material content, thus reducing the moulding cost in comparison to a solid item. A reduction in moulding cycle time and cooling time also means that more components can be produced in the same time period, cutting down on overall production costs.

DLS Plastics have been injection moulding using Gas Assist for well over 20 years, and have become experts in the design and manufacture of tools and components to make the most of gas assist injection moulding. The DLS design team will be involved early in the component design process allowing them to advise on the requirements that need to be considered for this style of moulding right from the start. We are able to develop designs to include efficient entry and exit points for the gas as well as reducing sharp edges and maintaining equal wall thicknesses. This helps ensure that moulding tools run smoothly, cleanly and efficiently, as well as producing well-made mouldings on every production run.

Call us today on 01476 564549 to discuss your project requirements with our design and sales team.

Need Help?
need help? Call or email us now. For all enquiries please feel free to contact a member of our staff using the details below:
+44 (0)1476 564549
+44 (0)1476 567538
[email protected]