Injection Molding
Custom injection molding from prototype to mass production. Aluminum and steel tooling, scientific molding processes, and a wide range of commodity and engineering resins.
About Injection Molding
Injection molding is the most efficient method for producing plastic parts at scale. Molten plastic is injected into a precision steel or aluminum mold cavity under high pressure, forming complex shapes with tight tolerances and excellent surface finishes in cycle times as short as 15 seconds.
FabRapid offers both rapid prototype tooling (aluminum molds in 15 days) and full production tooling (hardened steel molds for 1M+ shots). We mold 100+ commodity and engineering resins including ABS, nylon, polycarbonate, PEEK, and medical-grade materials. Our scientific molding approach uses pressure/temperature monitoring to ensure consistent part quality from the first shot to the millionth.
For projects transitioning from prototyping to production, our bridge tooling service provides aluminum molds for 10,000-50,000 unit runs while production steel tooling is being built — eliminating the traditional tooling delay.
Key Capabilities
Rapid Aluminum Tooling in 15 Days
Bridge the gap between prototyping and production with aluminum molds delivering 10,000+ shots. Validate designs with production-intent materials before investing in steel.
Production Steel Tooling
Hardened P20, H13, and S136 steel molds designed for 500K to 1M+ shot lifecycles. Multi-cavity, hot runner, and family mold configurations.
100+ Resin Options
From commodity resins (ABS, PP, PE) to engineering grades (nylon, PC, POM) to high-performance materials (PEEK, Ultem, LCP). Custom colors and additives available.
Scientific Molding Process
Pressure and temperature-controlled injection with real-time monitoring. Process validation and CPK documentation for medical and automotive quality requirements.
Insert Molding & Overmolding
Encapsulate metal inserts, threaded fasteners, or electronics within molded parts. Two-shot overmolding for multi-material and soft-touch applications.
Technical Specifications
How Injection Molding Works
DFM Analysis & Mold Design
Our engineers review your part design for moldability — wall thickness, draft angles, undercuts, gate location, and sink marks — before mold fabrication begins.
Tooling Fabrication
CNC-machined mold from aluminum (rapid tooling, 15 days) or hardened steel (production tooling, 4-6 weeks). Multi-cavity, family, and hot-runner configurations available.
T1 Sampling & Validation
First-article samples (T1) are produced and inspected against your requirements. Dimensional reports and material certifications are provided for approval.
Production & Quality Control
Scientific molding with real-time process monitoring ensures consistent quality. SPC (Statistical Process Control) and regular sampling maintain dimensional accuracy throughout the production run.
Our Injection Molding Services
Explore our specialized injection molding capabilities for your specific application.
Prototype Molding
Rapid aluminum tooling for prototype injection molded parts. Validate designs with production-intent materials before investing in steel tooling.
Production Tooling
Hardened steel production molds designed for 500K to 1M+ shot lifecycles. Multi-cavity, hot runner, and family mold configurations available.
Overmolding
Two-shot and overmolding for multi-material parts. Combine rigid substrates with soft-touch grips, seals, or color accents in a single molded part.
Insert Molding
Insert molding to encapsulate metal inserts, threaded fasteners, or electronic components within plastic parts for enhanced strength and functionality.
Compatible Materials
Materials available for injection molding.
Injection Molding FAQ
Aluminum molds cost 50-70% less and are fabricated in 15 days vs 4-6 weeks for steel. They are ideal for 5,000-50,000 shots. Steel molds are more expensive but last 500K-1M+ shots and support tighter tolerances, complex cooling, and textured surfaces. We recommend aluminum for prototype/bridge runs and steel for high-volume production.
There is no hard minimum, but injection molding becomes cost-effective at approximately 500+ units due to the tooling investment. For quantities under 200, consider urethane casting or CNC machining as more cost-effective alternatives.
Aluminum rapid tooling: 15-20 business days to T1 samples. Steel production tooling: 4-6 weeks to T1 samples. Production parts ship 1-3 weeks after mold approval. Total time from order to production parts is typically 6-10 weeks.
Ready to Start Your Injection Molding Project?
Upload your CAD file and get an instant quote. Most parts ship in 3-5 business days.