Injection Molding Project Cost Control: Factors Affecting Project Costs and Methods to Reduce Costs
Table of Contents
- Injection Molding Project Cost Control: Factors Affecting Project Costs and Methods to Reduce Costs
- Main components of injection molding project costs
- How much does it cost to make a standard injection mold?
- Factors affecting mold production costs in injection molding projects
- Various operational methods for cost optimization in injection mold projects
- All factors affecting the cost of injection molding projects
- Other variables directly related to the cost of injection molding projects
- How can we reduce the cost of injection molding projects ?
- Elimold: A reputable injection molding service provider
- in conclusion
Injection molding is a core process across various industries, enabling the efficient production of diverse plastic products and related components. Compared to other manufacturing methods, injection molding is renowned for its unparalleled versatility and high quality, making it the preferred choice for manufacturers of a wide range of plastic products . However, this technology is generally characterized by high associated costs . This article aims to delve into the various factors influencing injection molding costs and outline techniques for reducing overall costs.
Main components of injection molding project costs
Injection molding is a process primarily used for the mass production of identical parts with tight tolerances. This cost-effective and highly repeatable process allows for the mass production of high-quality parts. This fast, high-intensity process uses high temperature and pressure to inject molten material into a mold, the molten material depending on the manufacturing project. Various thermoplastics are used (including ABS, PS, PE, PC, PP, and TPU, etc.). The mold contains a cavity to hold the injected molten material, and the cavity design precisely reflects the final features of the part.
Based on the characteristics of this manufacturing process, we can easily conclude that the primary factor influencing the cost of injection molding projects is the cost of mold making. However, the cost of designing and manufacturing the mold depends on the required production volume, the complexity of the component design, the mold material, and the mold manufacturing process.
How much does it cost to make a standard injection mold?
Want to know the price of injection molds? You’re not alone. Injection molds are precision tools that mold molten plastic into consistent, high-quality parts, with manufacturing costs ranging from $3,000 to $30,000. The final price depends on factors such as design complexity, material selection, and production scale. Specifically, basic prototype molds typically cost between $3,000 and $8,000. Mid-range production molds typically cost between $10,000 and $25,000. High-end, complex molds usually start at $30,000 or more.
However, given the current development of metal 3D printing technology, the cost of simple, small-batch 3D printed molds can be as low as $100, while the design and manufacturing costs for large-scale production of complex molds can reach as high as $100,000. Although the fixed start-up costs of injection molding are quite high, the variable costs of this process are not high due to the use of inexpensive thermoplastic materials, short production cycles, and the ability to reduce labor requirements through automation and economies of scale. Low variable costs mean higher process efficiency, and if production volumes are high, the costs will be spread across hundreds or thousands of parts, resulting in a significant reduction in unit cost.
Factors affecting mold production costs in injection molding projects
The production cost of plastic injection molds for any type of injection molding project is influenced by a number of factors. Understanding these factors helps in the accurate estimation and optimization of costs for related injection molding projects. Below are key factors affecting mold production costs, summarized by injection mold engineers at Elimold.
| Part complexity | The complexity of part design directly affects mold production costs. Parts with complex features, undercuts, thin walls, or complex geometries require more complex mold designs and manufacturing processes, leading to increased costs. |
| Mold size and number of cavities | The physical dimensions of the mold and the number of cavities required for each molding cycle affect production costs. The larger the mold and the more cavities, the longer the required materials, processing, and assembly time, and the higher the cost. |
| Mold material | The choice of mold material affects initial cost and durability. High-quality mold materials, such as tool steel, have higher initial costs but longer lifespan and better performance. Material selection depends on part complexity, expected lifespan, and cost factors. |
| Mold complexity and features | The complexity of mold design and additional features (such as sliders, ejector pins, and inserts) increase the difficulty of machining and assembly, thereby increasing production costs. |
| Tolerances and surface requirements | Tighter tolerances and higher surface quality requirements necessitate more precise machining and polishing, increasing mold costs and requiring specialized equipment and technology. |
| Mold life and durability | Longer mold life and greater durability usually require high-quality materials, advanced surface treatments, and better structural design, which increases initial costs but reduces long-term maintenance and replacement costs. |
| Production volume | Production volume affects mold costs. Mass production requires more durable molds with optimized cooling and ejection systems, which involve larger upfront investments but lower unit costs; for small batches or trial production, low-cost solutions such as aluminum molds are more suitable. |
| Delivery time and urgency | Production lead time and urgency affect costs. Urgent orders may require expedited manufacturing, additional manpower, or priority procurement, resulting in extra costs. |
| Additional services and aftercare requirements | Post-construction services such as mold testing, sampling, modification, parts inspection, packaging, and transportation increase the overall mold cost. |
Various operational methods for cost optimization in injection mold projects
| Design for Manufacturing (DFM) | The design phase encourages close collaboration between part design engineers and mold manufacturers. Considering draft angles, wall thickness, and minimizing unnecessary features and undercuts helps simplify mold design and reduce manufacturing complexity and costs. |
| Material selection | Select appropriate mold materials based on expected production volume and component requirements. Choose materials that offer high cost-effectiveness while meeting performance requirements. Balancing material costs with expected lifespan and maintenance needs helps optimize costs. |
| Simplify mold design | Keep the mold design as simple and functional as possible. Reduce the number of components, eliminate redundant features, and simplify the ejection and cooling systems. Simplifying the design reduces manufacturing complexity, machining time, and assembly costs. |
| Standardized components | Standardized mold components such as ejector pins, guide pins, and leader pins significantly reduce costs. Standard parts are readily available and inexpensive, and are easy to replace and maintain, simplifying the maintenance process. |
| Optimize the number of cavities | The appropriate number of cavities should be determined based on production volume requirements. Increasing the number of cavities can improve production capacity and reduce unit cost. However, it is necessary to balance the number of cavities with part quality, cycle time, and machine capacity. |
| High-efficiency cooling system design | Optimize the cooling system to shorten cycle time. Employ cooling channels that conform to the part shape to achieve uniform cooling and shorten cycle time. Efficient cooling reduces energy consumption, improves part quality, and increases production efficiency. |
| Manufacturing process selection | Choose the appropriate tools and processes based on production volume and part complexity. For small batches or trial production, economical solutions such as 3D printing or soft molds can be used. For mass production, hardened steel molds are more durable. |
All factors affecting the cost of injection molding projects
The cost of injection molding is not fixed and varies depending on the process. Custom injection molding can cost anywhere from several thousand dollars to hundreds of thousands of dollars. The following will discuss some factors related to the cost of injection molding:
custom manufacturing plastic molds
Molds are an expensive piece of equipment in the injection molding process. While mold making is a one-time investment, it is crucial to the overall cost of the process. Molds are typically manufactured using CNC machining, EDM, and 3D printing technologies. These precision machining techniques are used to create the mold and related components, which are then assembled into the mold required for the injection molding project . However, 3D printing technology is now commonly used for faster mold manufacturing and cost savings . This technology largely eliminates the need for skilled workers, thus significantly reducing mold costs. Although 3D printed molds are cost-effective, they may experience shrinkage, and their size and specifications are also limited.
Operating costs of injection molding production equipment
The cost of injection molding also depends on the type of equipment used. This process requires a wide variety of equipment, ranging from small to large machines with varying functions and specifications. The types of equipment used in this process include electric injection molding machines, hydraulic injection molding machines, and hybrid injection molding machines. Generally, electric injection molding machines may have a higher initial budget, but they have an advantage in operating costs due to their lower energy consumption. Hydraulic injection molding machines use hydraulic pumps to perform their function ; they are less expensive and provide stable ejection and injection. However, their operating costs can be higher due to their higher energy consumption. On the other hand, hybrid injection molding machines combine the features of hydraulic and electric injection molding machines , and their cost is relatively more suitable for producing mid- to high-end plastic products.
Material and additive costs
A wide variety of plastic resins can be used in injection molding projects, such as PC, PE, PU, and ABS. Their availability, price, and performance are crucial in determining the total cost of injection molding. The final cost of the plastic depends on the type of design and the amount used, typically increasing by a few dollars per kilogram.
Manufacturing cost of injection molded parts
The cost of injection molded parts depends on the complexity of the mold. It includes costs related to the design, size, and volume of the injection molded component. Since the parts are not pre-made, additional post-processing costs, such as surface treatment, sandblasting, and polishing, are often incurred when preparing the mold.
Labor costs
A significant cost of this process is labor cost, including the installation, maintenance, and operation of the injection molding machine. Installation costs include the associated costs for each stage of installation. While maintenance and operation costs are relatively small, they have a significant impact on the total cost of the injection molding process.
Other variables directly related to the cost of injection molding projects
In addition to the various common factors that affect the cost of injection molding projects mentioned above, there are several other variables that can influence the cost of injection molding projects, including the following:
Component dimensions
The larger the part to be injection molded, the larger the mold needed to house it. Larger parts often require more injection material to complete the production cycle. Larger molds are generally more expensive to manufacture than smaller molds of the same design.
Component Design
If a component design involves complex geometry, a complex mold is required to execute the project. Mold design typically involves two surfaces: surface A and surface B. Surface A, also known as the outer surface, is usually the side visible to the user. Surface A should be smooth and aesthetically pleasing. Surface B contains hidden structures that support the component’s purpose. Surface B structures may include reinforcing ribs and supports, and its surface is usually much rougher than surface A. Molds with complex AB surface designs are generally more expensive to manufacture than simpler molds. Complex designs with grooves may also require sliding side core pulling and cores, further increasing mold costs.
Yield
The manufacturing techniques and material quality used in mold making depend on the number of injection-molded parts. Small-batch projects may only require 3D-printed or simply machined aluminum molds, while large-scale production requires high-grade steel molds, and may even necessitate the use of multiple molds to ensure smooth operation and prevent production quality issues caused by mold wear. This leads to increased mold costs, but the additional cost of large-batch molds is spread across more parts, resulting in lower unit costs.
Component volume and cavity size
Part volume refers to the size of the mold cavity. The more cavities a mold requires, or the larger the cavity volume, the longer the pressure time. Increasing the pressure time slows down the production process and ultimately leads to increased costs.
How can we reduce the cost of injection molding projects ?
Based on Elimold’s experience with over 10,000 projects, it’s clear that in today’s highly competitive market, OEM manufacturers are focused on reducing the overall cost of injection molding projects and are eager to understand which optimizations can significantly lower mold and injection production costs. Therefore, we have summarized the following operations that can significantly reduce injection molding project costs.
Design for Manufacturing (DFM) Analysis
Manufacturers typically use Design for Manufacturing (DFM) to reduce the overall cost of injection molding. In DFM, the design of manufactured parts is done under the premise of manufacturability, within the customer’s budget, and to meet the required application. Various scientific techniques are used to determine efficient designs and process flows, thereby reducing costs.
Simplify part structure and use universal molds
Another way to reduce injection molding costs is to simplify the overall design of the part. This will reduce the manufacturing cost of complex molds and save money by eliminating the extra functions of the part. In this case, a universal mold can also be used, thereby reducing mold manufacturing costs.
Replace with cheaper materials and inserts
The choice of injection molding material also affects the cost of injection molding. Using ABS or polypropylene can significantly reduce production costs. Another way to reduce costs is to use insert molding, as it eliminates the need to machine threads into the plastic to connect it to the metal part.
Reduce the number of mold cavities
The number of cavities in a mold is directly proportional to its cost. Therefore, to reduce mold costs, manufacturers seek molds with the fewest possible cavities. Mold flow analysis is crucial in this process because it can provide optimized design options for parts and identify areas where cavities can be eliminated.
Use self-fitting parts
Using self-fitting parts can also reduce the overall cost of injection molding. It saves injection molding costs by simplifying the design process. Self-fitting parts can be connected by rotating 180 degrees, so the entire part can be manufactured using a single mold half.
Elimold: A reputable injection molding service provider
Elimold is a leading manufacturer of custom plastic injection molded parts, supplying a wide range of injection molded products and parts. Headquartered in Shenzhen, China, we have been operating for over 15 years. Our expertise and experience allow us to meet the requirements of all our clients, and we consistently strive to provide you with the highest quality products. Moreover, we offer more than just professional injection molding services; we specialize in highly specialized mold making and injection molding services, producing high-performance parts at competitive prices. Our products are designed to meet the needs of various industries worldwide, including automotive parts and equipment for refrigerators, washing machines, dishwashers, and other household appliances. If your production line requires the best plastic injection parts at the best cost, please contact us today.
in conclusion
Injection molding production cost control is a systematic and long-term task that requires continuous optimization and improvement at every stage in collaboration with Elimold’s injection molding engineering team. Currently, we can implement effective measures for production cost control, enhancing competitiveness and the profitability of our clients’ projects. During implementation, our team flexibly applies these methods, continuously improving relevant processes based on the specific circumstances of different client companies, and constantly responding to market changes and challenges—this is key to helping our clients achieve project success. We hope the methods summarized in this article will provide you with substantial assistance, enabling your company to stand out in the fierce market competition and achieve comprehensive production cost control. If you require professional injection molding services, please contact Elimold’s professional team.