Fathom manufactures high-quality injection molded parts through modern methods, incorporating the latest in advanced injection molding technology. Clients from many industries trust Fathom with their injection molding projects requiring high complexity and high precision. Our manufacturing network ensures our customers’ time-sensitive and short production-run-related projects are finished on time.
Injection molding is a manufacturing process used to mass produce plastic parts. During injection molding, molten plastic is injected into a mold using high pressure. Once the plastic has cooled, the part is released from the mold. Injection molding is highly repeatable and allows for identical parts to be produced quickly and in large volumes. There are cost considerations for injection molding, which include mold making, cost of materials and setup.
Mold or tooling costs account for a large part of the price of injection molding. The mold will be manufactured by CNC machining, electrical discharge machining, or 3D printing. CNC machining is typically used when a stainless steel or aluminum mold with a high level of precision is required. The EDM process is utilized for complex molds that cannot be made using traditional manufacturing methods. 3D printing is a good match for low to mid-volume projects.
The cost of materials largely depends on the materials chosen and the amount needed. A few of the most common materials used for injection molding include polypropylene, polyethylene and acrylonitrile butadiene styrene (ABS). All three of these materials are popular due to their durability and affordability.
The injection molding process from tooling to production is mostly automated. The setup cost includes the time required to make the mold pre-cycle and any additional time to configure the equipment to make the product. For large production runs, any setup fees are amortized as more and more products are made.
In addition to tooling, materials, and setup, the cost of injection molding can be affected by a part’s size, design, and quantity ordered. The cost of your project can be reduced or increased by these factors. Maximize your budget by paying close attention to these three key details.
As the size of a part increases, the cost of injection molding may increase, too. The cost increase is attributed to the size limitations of injection molding machines. It is sometimes necessary to produce a larger part in multiple pieces, which means an extra step must be added for assembly. The extra step creates a longer lead time. Larger parts may also require different equipment, tooling, and setup. Lastly, because larger parts need more material to produce, the cost is increased.
The complexity of a part will also impact its cost. Complex parts may require additional tooling when compared to simple parts. Secondary processes may also be needed to add complex features. Costs can be reduced by removing unnecessary features, eliminating undercuts, modifying mold design, and adjusting the size. Simple parts that are free from undercuts are the most affordable to manufacture.
Injection molding is a popular manufacturing method for high-volume production runs. The more units produced, the lower the price per unit. In addition to lower costs per part for higher production runs, injection molding can reduce the cycle time while increasing accuracy and quality.
Let Fathom help you manufacture high-quality, and cost-effective injection molded parts. Fathom is a single-source global solution ready to support both low- and high-volume jobs. Our team incorporates both additive and advanced technologies, resulting in high-quality parts that will meet your customers’ needs.
Injection Molding is just one of 28 manufacturing processes offered by Fathom.
Use Fathom’s SmartQuote online platform to receive a quote in as fast as 1 hour, usually within 24 hours. Whether you need injection molding or another manufacturing service, Fathom’s injection molding lead times are as follows:
Fathom’s manufacturing facilities are powered by over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. Sixteen of Fathom’s machines are dedicated to injection molding. It is our network of state-of-the-art equipment that allows us to offer our customers a rapid turnaround.
Fathom also offers hybridized services that leverage injection molding. Do you need injection molding as part of a more complex project? Fathom can deliver. A recent case study illustrates how Fathom manufactured 20,000 parts in 27 days using 55+ tools, including injection molding services.:
A customer came to Fathom with a complex project that spanned the technologies and processes of rapid production—and needed it done fast. Fathom delivered.
55+ Tools to Injection
Mold 15,000 Parts
First Article in 2 Weeks
3,000+ 3D
Printed Parts
2,000+ Metal
Fabricated Parts
3D Printing / Additive Manufacturing—PolyJet, SLS, MJF.
DFM Analysis + CAD Mods.
CNC Machining. Laser Cutting.
Stamping. Die Cutting. Post-Opp Drilling.
24-hour Turnaround Urethane Casting.
Injection + Compression Molding.
Model Finishing. Insert Assembly.
Advanced Project Management.
Fathom has 2 US-based locations that offer injection molding, offering nationwide coverage to the entire United States. Fathom’s advanced prototyping and manufacturing services include wire EDM, CNC machining, chemical etching, metal 3D printing, and more. We have provided over 200,000 quotes to leading US companies and are ready to provide you with a quote today.
Locations include:
HEADQUARTERS
1050 Walnut Ridge Drive
Hartland, WI 53029
ISO 9001:2015
AS9100:2016
ITAR
ILLINOIS
1207 Adams Drive
McHenry, IL 60051
Knowing injection molding specifications and tolerances will ensure that parts fit correctly during assembly. Tolerances and specifications also determine how a part should be shaped to maximize function. Parts with a normal tolerance (+/- 0.005 inches in variation) are less expensive to produce than parts with a tight tolerance (+/- 0.002 inches) or very tight tolerance (+/- 0.001 inches). The optimal tolerance for a part is critical for making a premium part at an affordable price.
| TOOL OPTIONS | LEAD TIME | PART QUANTITY | MAXIMUM PARTING LINE MISMATCH | MAXIMUM FLASH | TOOL TOLERANCES LINEAR DIMENSIONS | PART COLOR | PART FINISH (COLOR) | PART FINISH (TEXTURE) |
|---|---|---|---|---|---|---|---|---|
| Rapid Tool (Master Unit Die Base) | 1.5-3 Weeks | 5,000 Shots | 0.010in | 0.010in | ±0.003 + 0.002in/in | Pantone Colors | A2 | Yes |
| Prototype Tool (Stand Alone) | 2-4 Weeks | 5,000-50,000 Shots | 0.010in | 0.007in | ±0.005 + 0.002in/in | A2 | ||
| Production Tool | 5-10 Weeks (Depends on Size and Complexity) | 250,000 - 1,000,000 Shots (Depending on Class of Tool Selected) | 0.005in | 0.005in | SPI (Commercial) | A1 |
Selecting the best material for your unique project is important because it can affect the part’s performance. When picking a material, consider the environment in which the part will function and how the part is expected to function. A material’s durability, color, flexibility, strength, and cost are all important. Here are some of the materials offered by Fathom for the injection molding process.
Injection molding is an efficient manufacturing process that has multiple benefits. Injection molding is best known for its ability to produce identical products at a fast production rate. This quick turnaround is facilitated by automation, which also helps to reduce labor costs and overhead. The high pressure used during injection molding makes it possible to add intricate details to a part. A variety of different resins may be combined in injection molding. Fillers may be added to the material to enhance strength.
After the injection molding process, some parts may require a surface finish. The surface finishing step can add a rough or smooth texture to a part. Industrial, mechanical, or construction parts may require a rough finish. Items such as toys or medical supplies may need a smooth or glossy finish. Below is a list of surface finishes offered by Fathom.
| SURFACE FINISH | GUIDE | TYPICAL APPLICATIONS |
|---|---|---|
| Standard No Machine Mark | Tool Marks Removed | Low Cosmetic |
| SPI-C1 | 600 Stone | Low Polish Parts |
| SPI-B1 | 600 Grit Paper | Medium Polish Parts |
| SPI-A2 | Grade #6 Diamond | High Polish Parts |
| SPI-A1 | Grade #3 | Lens or Mirror |
| IM-1 Light Bead Blast | Need 1 Degree Draft Angle | |
| IM-2 Medium Bead Blast | Need 1.5 Degree Draft Angle | |
| IM-3 Heavy Bead Blast | Need 3 Degree Draft Angle |
Many industries use injection molding, including industrial, commercial, consumer goods, medical, sporting goods and more. Injection molding can be used for small and large parts, even parts weighing over a hundred pounds. Examples of injection molded parts include:
A: Yes, Fathom offers injection molding services.
A: Injection molding is a manufacturing process commonly used for plastic parts. During injection molding, molten plastic is injected into a two-part mold using high pressure. Once the part has cooled inside the mold, it is ejected. The part may or may not require a secondary finish.
A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: The cost of injection molding depends on the complexity of the part, part size, tooling cost, equipment setup and configuration, materials used, and more. Contact Fathom today for a quote.
A: Injection molds have a higher upfront cost because they can be used repeatedly to produce thousands of identical parts.
A: The best way to estimate the cost of your injection molding part is to use the SmartQuote platform and receive a quote in as fast as 1 hour.
A: A high-quality, well-maintained injection mold can last from 100,000 to 1 million cycles.
Ready to calculate costs or receive a quote on your Injection Molding project? Get started today. Get a fast quote on any design
Precision manufacturing
from coast to coast.
HEADQUARTERS //
1050 Walnut Ridge Drive
Hartland, WI 53029
877-328-4668
ARIZONA
444 W. 21st St. Ste. 101
Tempe, AZ 85282
480-966-2300
CALIFORNIA
46758 Lakeview Blvd
Fremont, CA 94538
COLORADO
7770 Washington St.
Denver, CO 80229
303-288-6855
FLORIDA
14000 N.W. 58th Court
Miami Lakes, FL 33014
305-889-3280
ILLINOIS
1207 Adams Drive
McHenry, IL 60051
815-385-7500
1401 Brummel Ave
Elk Grove, IL 60007
847-952-8088
MINNESOTA
13758 Johnson Street NE
Ham Lake, MN 55304
763-755-7575
NEW YORK
1920 Slaterville Rd.
Ithaca, NY 14850
607-277-7070
401 W. Shore Blvd.
Newark, NY 14513
315-331-7680
TEXAS
1513 Sam Bass Rd.
Round Rock, TX 78660
512-255-1477
