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Injection Molding Service | Stratasys Direct

Injection Molding Service

Expert Injection Molding for High-Quality, Durable Parts – Every Time

ISO9001 & AS9100 QMS | DDTC/ITAR Registered
Injection Molded Part Service | Stratasys Direct

Your Single-Source Manufacturing Leader

From additive manufacturing to injection molding, from prototype to production.

As a full-service supplier, we streamline the manufacturing process of prototypes and ongoing production parts by eliminating the need to coordinate multiple vendors, saving you time and money. Our experience in advanced manufacturing spans both Additive Manufacturing (AM) and Injection Molding (IM), enabling us to recommend the ideal solution for each stage of your product development cycle. 

With manufacturing facilities in the US and China, Stratasys Direct builds molds using high-grade P20 steel or harder, ensuring top-tier mold quality and adherence to Classes 103 to 105 mold classification standards. Our US-based Project Engineering and Production Coordination teams manage all projects, with hands-on oversight provided by our team in Shenzhen, China.

We provide complementary DFM services to optimize IM parts without compromising design integrity, as well as consultation if transitioning from IM to AM or AM to IM. This seamless transition between additive and conventional manufacturing, combined with our ability to handle insert molding and over-molding, makes Stratasys Direct stand out as the go-to partner for your projects.

Enjoy Limitless Material Options

Stratasys Direct offers a vast selection of injection molding materials, with access to thousands of thermoplastics. We even accommodate custom compounding, ensuring greater versatility and performance to meet your specific project requirements. A few of the more popular injection molding materials:

 

ABS Injection Molding Pellets | Stratasys Direct

Key Features

  • Good impact resistance with toughness and rigidity
  • Metal coatings have excellent adhesion to ABS
  • Excellent processability and appearance

Applications

  • Computer housings
  • Musical instruments (recorders & plastic clarinets)
  • Telecom devices
  • Small appliances (enclosures)
  • Automotive (interior trim, wheel covers, emblems)
  • Medical components
Popular for its strength and detail, injection molded ABS produces parts with high detail and features. It’s commonly used for molded prototypes and mid to high-volume production applications.
Additional Resources

Injections Molding Design Guide

Acrylic (PMMA) Injection Molding Pellets | Stratasys Direct

Key Features

  • Excellent optical clarity
  • Excellent weatherability and resistance to sunlight
  • Rigid with good impact resistance
  • Good light transmission

Applications

  • Automotive transparent items such as head/tail lenses and trim
  • Household light fixtures and decorative items
  • Safety equipment and shields
Material with resistance to breakage often used for transparent applications.
Additional Resources

Injections Molding Design Guide

Nylon Injection Molding Pellets | Stratasys Direct

Key Features

  • Temperature capability 600°-700° for short term
  • Excellent chemical resistance
  • High resistance to abrasion
  • Tough and withstands repeated impact

Applications

  • Automotive components
  • Bearings
  • Electronic connectors
  • Gears
  • Consumer products
  • Industrial products
Injection molded Nylon is an ideal option for high volume production of strong, heat resistant and repeatable components.
Additional Resources

Injections Molding Design Guide

Nylon Glass Fibers Injection Molding Pellets | Stratasys Direct

Key Features

  • Increase mechanical strength
  • Enhanced stiffness and stability
  • Improved thermal properties
  • Enhanced wear resistance

Applications

  • Under-hood automotive applications
  • Gears & bearings
  • High strength-to-weight applications in aerospace
  • Applications required thermal stability, impact resistance
Injection molded Nylon 32% glass fiber produces enhanced properties from typical nylon reinforced for added rigidity and wear resistance.
Additional Resources

Injections Molding Design Guide

Polycarbonate Injection Molding Pellets | Stratasys Direct

Key Features

  • High impact resistance
  • Clarity
  • Dimensional stability
  • Chemical resistance (PC blends)

Applications

  • Automotive headlights
  • Business machines
  • Consumer products
  • Telecommunications
  • Medical products
  • Mechanical goods
Injection molded polycarbonate is a versatile thermoplastic for high volume production of strong components.
Additional Resources

Injections Molding Design Guide

Polycarbonate / ABS Injection Molding Pellets | Stratasys Direct

Key Features

  • Good impact resistance with toughness and rigidity
  • Metal coatings have excellent adhesion to ABS
  • Very good indoor UV light color stability
  • Excellent processability and appearance

Applications

  • Automotive exterior and interior components
  • Medical hardware
  • Electrical housings
  • Computers
  • Monitors
  • Business equipment housings
  • Enclosures
Injection-molded polycarbonate / ABS blend provides an ideal consolidation of the best mechanical properties of PC and ABS for use across a range of industries and applications.
Additional Resources

Injections Molding Design Guide

PEI Injection Molding Pellets | Stratasys Direct

Key Features

  • High heat resistance
  • Exceptional strength and impact modulus
  • High dielectric strength
  • Broad chemical resistance
  • Biocompatible
  • Excellent machinability and finishing characteristic
  • Outstanding processability on conventional molding equipment
  • Flame resistance with low smoke evolution

Applications

  • Commercial aircraft interiors
  • Healthcare products
  • Cooking utensils
  • Fiber optics
  • Electrical products
  • Electronic parts
Polyetherimide is a high-performance thermoplastic with characteristics similar to PEEK. It is frequently used as a replacement for metal components in industrial and structural elements.
Additional Resources

Injections Molding Design Guide

Polyoxymethylene Injection Molding Pellets | Stratasys Direct

Key Features

  • High tensile strength with rigidity and toughness
  • Good impact and solvent resistance
  • Glossy molded surface
  • Low static and dynamic coefficients of friction (slippery)
  • Many grades have FDA and NSF approvals on food and water contact
  • Replace die-cast metal components

Applications

  • Mechanical automotive
  • Business machines
  • Household appliance
  • Gears
  • Bushings
  • Door handles
  • Seat belt parts
Injection molded polyoxymethylene produces precise parts for applications requiring high stiffness, low friction and low water absorption. It is widely used in the automotive and consumer electronics industries.
Additional Resources

Injections Molding Design Guide

Polypropylene (PP) Injection Molding Pellets | Stratasys Direct

Key Features

  • Excellent moisture resistance
  • Food grades available
  • Mold–in hinge possible
  • Good impact strength

Applications

  • Packaging
  • Industrial components for fluid processing
  • Household goods
  • Automotive
  • Electrical hardware
Injection molded Polypropylene is chemical resistant, elastic, and fatigue resistant making it ideal for high volume production of consumer product applications.
Additional Resources

Injections Molding Design Guide

Polystyrene Injection Molding Pellets | Stratasys Direct

Key Features

  • Optical clarity
  • High gloss
  • FDA grades available
  • Low cost
  • Good dimensional stability
  • Good rigidity

Applications

  • Household goods
  • Containers
  • Furniture
  • Housings
  • Packaging
Lightweight material popular for its high impact strength and toughness.
Additional Resources

Injections Molding Design Guide

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Customized Quotes for Your Injection Molding Needs

At Stratasys Direct Manufacturing, we prioritize your unique needs, offering tailored quotes based on your specific requirements. Unlike competitors, our Design for Manufacturing (DFM) approach adheres to industry standards rather than solely relying on our established norms, ensuring precision and adaptability. This means online quoting is not sufficient and a discussion with our experts is the best way to make sure your project is executed correctly.  

To obtain a quote, simply fill out the tooling form on our website, and our team will promptly reach out to schedule a meeting. We look forward to discussing your project in detail and providing a comprehensive solution that meets your expectations. 

Injection Molding Form | Stratasys Direct

Seamless Finishing and Assembly Services

Stratasys Direct stands out when it comes to finishing and assembly for Injection Molding (IM). Our secondary operations include light assembly, heat-staking, ultrasonic welding, and precise printing and engraving techniques. With a dedicated team of finishing and assembly experts, we guarantee your project is executed to the highest standards, ensuring it is primed and ready for the market.

Injection Molding Quality Assurance | Stratasys Direct

Unwavering Commitment to Quality & Timely Delivery

Stratasys Direct Manufacturing sets the benchmark for quality and excellence in Injection Molding. Our industry-leading On-Time Delivery (OTD) and quality metrics are consistently 99% and above. Our seasoned professionals in the US and China, ensure consistent, superior results, fostering trust from our customers and recognition for our commitment to excellence. 

Injection Molding Design Guide | Stratasys Direct

Injection Molding Design Guide

Injection molding, utilized for producing diverse parts ranging from small battery boxes to large truck body panels, involves designing a mold precisely machined to replicate the desired part features. This comprehensive design guide addresses key considerations such as material selection, wall section design, warp prevention, voids and shrinkage management, as well as detailing aspects like ribs, bosses, draft angles, texture, sharp corners, and insert.

Injection Molding Benefits

Rapid Delivery

In-house project engineering, production coordination, and top-tier mold quality ensure the highest quality parts are delivered on schedule.

Large Volumes

Produce high volumes of consistent production parts with near-limitless plastic material options.

Quality Production Parts

Get precise, repeatable parts throughout large production at the quality you expect.

Rapid Delivery

In-house project engineering, production coordination, and top-tier mold quality ensure the highest quality parts are delivered on schedule.

Large Volumes

Produce high volumes of consistent production parts with near-limitless plastic material options.

Quality Production Parts

Get precise, repeatable parts throughout large production at the quality you expect.

From one-off prototypes, to low-volume production, we have the experience and engineering know-how to support you

Contact Us
What is injection molding | Stratasys Direct

What Is Injection Molding?

Injection molding is the most commonly used method for producing higher-volumes of plastic parts. Simply put, it is the process by which plastic or rubber materials are heated above their melting point and injected into a mold to create the desired shape. The part is cooled and ejected from the mold, and the gate is trimmed from the part.  

The injection molding process uses granular plastic pellets that are gravity-fed from a hopper. A screw-type plunger forces the material into a heated chamber, called a barrel, where it is melted. The plunger continues to advance, pushing the polymer through a nozzle at the end of the barrel that is pressed against the mold. The plastic enters the mold cavity through a gate and runner system. After the cavity is filled with material, a holding pressure is maintained to compensate for material shrinkage as it cools.

At this same time, the screw turns so that the next shot is moved into a ready position, and the barrel retracts as the next shot is heated. Because the mold is kept cold via cooling lines, the plastic solidifies soon after the mold is filled. Once the part inside the mold cools completely, the mold opens, and the part is ejected. The next injection molding cycle starts the moment the mold closes and the polymer is injected into the mold cavity.

Steel injection molded tool | Stratasys Direct

Molds are typically constructed from pre-hardened steel, hardened steel, aluminum, and/or beryllium-copper alloy. Of these materials, hardened steel molds are the most expensive to make, but offer the user a long lifespan, which offsets the cost per part by spreading it over a larger quantity. 

The most economical molds are produced out of aluminum but are prone to wear and breakage causing out-of-spec parts or interruptions in delivery timelines. For this reason, these are used when lower volumes of parts are needed. Pre-hardened steel molds can withstand higher volumes of parts vs. aluminum but are more difficult to machine which increases upfront machining costs. Hardened steel tools are used for high-volume production runs and can maintain high-quality surface finishes over a large number of molded parts. Hardened steel tools can exceed 1,000,000 million molded parts. Beryllium copper is often used in special applications requiring fast heat removal or places that see the most shear heat generated, and are also used where large quantities of parts are required. 

Our team comprises industry veterans with extensive knowledge and hands-on experience in injection molding, ensuring that we understand the nuances and complexities of every project. Unlike many competitors who prioritize quick turnaround times at the expense of quality, our approach ensures that each mold is crafted with the utmost precision and durability, designed to withstand the demands of production without compromising on the integrity of the final product.

Injection Molding Resources

A machined injection mold | Stratasys Direct

How Design and Material Choices Impact Injection Molding Costs

Unlock efficient injection molding with optimized design, uniform thickness, proper draft angles, and smart material selection. Stratasys Direct provides expert support for cost-effective, high-quality production.

View more
3D Printing or Injection Molding? | Stratasys Direct

3D Printing and Injection Molding: A Practical Guide on How to Choose

A practical guide featuring key points to consider when choosing 3D Printing or Injection as a part manufacturing method.

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Additive Manufacturing and Injection Molding Webinar

The Union of Additive Manufacturing and Injection Molding

The Additive Manufacturing and Injection Molding webinar guides you through these manufacturing technologies from prototyping parts to production parts.

View more
im design

Three Mistakes to Avoid when Designing for Injection Molding

This article details three mistakes designers should avoid for successful injection molded parts.

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The opaque flexible material has been over-molded into the transparent rigid material. This was achieved via a single print.

3D Printing and Molding: Finding the Right Process to Manufacture Over-Molded Designs

Wherever you are in your design process, you’re not limited in manufacturing solutions. Learn more about designing over-molded parts.

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Injection Molding Design Guide | Stratasys Direct

Injection Molding Design Guide

Injection molding is used to manufacture everything from AAA battery boxes to truck body panels. Get key injection molding design considerations in this guide.

View more
implementing 3d printing

Five Steps to Mass Production

Beginning mass production doesn’t have to be a scary leap into the unknown. We’re highly experienced in bringing products to market successfully.

View more
A machined injection mold | Stratasys Direct

Unlock efficient injection molding with optimized design, uniform thickness, proper draft angles, and smart material selection. Stratasys Direct provides expert support for cost-effective, high-quality production.

3D Printing or Injection Molding? | Stratasys Direct

A practical guide featuring key points to consider when choosing 3D Printing or Injection as a part manufacturing method.

Additive Manufacturing and Injection Molding Webinar

The Additive Manufacturing and Injection Molding webinar guides you through these manufacturing technologies from prototyping parts to production parts.

im design

This article details three mistakes designers should avoid for successful injection molded parts.

The opaque flexible material has been over-molded into the transparent rigid material. This was achieved via a single print.

Wherever you are in your design process, you’re not limited in manufacturing solutions. Learn more about designing over-molded parts.

Injection Molding Design Guide | Stratasys Direct

Injection molding is used to manufacture everything from AAA battery boxes to truck body panels. Get key injection molding design considerations in this guide.

implementing 3d printing

Beginning mass production doesn’t have to be a scary leap into the unknown. We’re highly experienced in bringing products to market successfully.

3D Printing Services

3d printed SAF automotive grill insert

SAF® 3D Printing Service

Discover how Selective Absorption Fusion (SAF®) 3D printing technology operates and how it can be used to help lower production costs for your next project.

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SLS 3d printed remote control car Stratasys Direct

SLS 3D Printing Service

Selective Laser Sintering (SLS) is a 3D printing technology that creates tough and geometrically complex components for batch or serial manufacturing.

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MJF 3D Printing Service

Learn more about Multi Jet Fusion printing technology and how it can provide a faster, more cost-effective process for 3D-printed parts.

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3d printed FDM vehicle bumper Stratasys Direct

FDM® 3D Printing Service

Get parts using the most widely used form of 3d printing from those who invented FDM®

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P3 DLP cable management Stratasys Direct

P3™ DLP 3D Printing Service

P3™, an evolution of DLP 3D printing, produces finely detailed 3D-printed parts using high-performance materials.

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3D Printed Stereolithography SLA part for investment casting

SLA 3D Printing Service

Learn more about Stereolithography (SLA) 3D printing technology and how it rapidly builds components using a UV laser to cure a photoreactive resin.

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3d printed polyjet color shoe

PolyJet™ 3D Printing Service

PolyJet is a 3D printing technology that jets and cures layers of liquid photopolymer to build high-resolution models, prototypes and full color display models.

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3d printed SAF automotive grill insert

Discover how Selective Absorption Fusion (SAF®) 3D printing technology operates and how it can be used to help lower production costs for your next project.

SLS 3d printed remote control car Stratasys Direct

Selective Laser Sintering (SLS) is a 3D printing technology that creates tough and geometrically complex components for batch or serial manufacturing.

multi jet fusion functional prototyping

Learn more about Multi Jet Fusion printing technology and how it can provide a faster, more cost-effective process for 3D-printed parts.

3d printed FDM vehicle bumper Stratasys Direct

Get parts using the most widely used form of 3d printing from those who invented FDM®

P3 DLP cable management Stratasys Direct

P3™, an evolution of DLP 3D printing, produces finely detailed 3D-printed parts using high-performance materials.

3D Printed Stereolithography SLA part for investment casting

Learn more about Stereolithography (SLA) 3D printing technology and how it rapidly builds components using a UV laser to cure a photoreactive resin.

3d printed polyjet color shoe

PolyJet is a 3D printing technology that jets and cures layers of liquid photopolymer to build high-resolution models, prototypes and full color display models.

Stay updated on the latest 3D printing news!

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