Large Part Injection Molding Manufacturing
Molding large plastic parts can be a demanding process. Even the smallest details hold great importance and can impact the efficiency of production and the success of the final product. Choosing the right manufacturing partner is critical for producing large plastic parts, as this process requires presses with adequate tonnage capabilities and certain technical expertise.
AdvancTEK is a large part injection molder built for that requirement. Our presses run from 65 tons to 3,500 tons, a range that covers mid-size housings through large injection molded parts measured in feet rather than inches. When a program needs capacity beyond that range, we are willing to invest in the equipment to support it.
With our capable machinery, skilled specialists, and inventive ideas, AdvancTEK produces quality, cost-efficient plastic solutions. Innovation and success always remain within our view. Our team leaps to new and competitive levels to ensure we surpass our customers’ expectations each and every time.
How Large a Part Can AdvancTEK Injection Mold?
Our largest press delivers 3,500 tons of clamp force. Clamp tonnage is the practical ceiling on part size in injection molding, because the press has to hold the mold closed against the pressure of the injected resin. A larger projected part area demands more tonnage, which is why injection molding large parts is a capability question before it is a design question.
Size limits by process:
- Injection molding – Presses from 65 tons to 3,500 tons
- Reaction injection molding – Clamps up to 3 feet by 10 feet
- Thermoforming – Sheet sizes up to 6 feet by 8 feet
Confirming the size envelope during quoting keeps tooling decisions from being revisited after a mold is cut. AdvancTEK is also prepared to invest in larger or unique capital equipment when a program justifies it. Full injection molding capabilities cover the complete 65-to-3,500-ton range.
Tell Us About Your Project
Share a few details about your project, and our team will follow up with next steps.
Large Part Molding Applications
AdvancTEK provides large part plastic injection molding solutions for the following applications:
- Hoods, roofs, door panels, and other interior and exterior plastics for UTVs, ATVs, LSVs, and golf carts
- Medical device housings
- Construction and agricultural equipment
- Telecommunication antenna housings
- Security towers
- Electronic enclosures
- Material/parcel handling
- Energy storage and battery systems
- Marine components
- Warehouse automation
Our Large Part Molding Capabilities
AdvancTEK specializes in large part injection molding, thermoforming, and reaction injection molding (RIM). We also offer design and development services, wherein we consider all aspects of your desired product to provide you with the most efficient manufacturing strategy. In addition to the capabilities listed below, AdvancTEK is willing to invest in larger or unique capital equipment if needed to help bring your project to fruition.
Injection Molding
- 65T – 3500T
Thermoforming
- Sheet size up to 6’ to 8’
- Vacuum forming
- Pressure forming
- Twin-sheet molding
Reaction Injection Molding
- Clamps up to 7’ to 10’
Why You Should Choose AdvancTEK for Injection Molding Large Parts
As a large part injection molder, we have the flexibility to select the best approach for your project, thanks to our in-house tooling, design, and process engineering capabilities. In addition to flexibility, by working with us to develop custom injection molding of large parts, you’ll reap benefits including:
- Minimized risk of disruption – Our large-tonnage machines in both the U.S. and Mexico provide built-in production redundancy to keep operations running smoothly.
- Cost-efficiency – We understand how cost efficiency is a key focus when creating custom injection molding large parts. We employ many strategies to optimize costs, such as adjusting the wall thickness to reduce the need for high-tonnage machines.
- Versatility – We are a world-class partner with the ability to deliver solutions for customers in various industries including industrial, battery and energy storage, telecommunications, powersports, construction and more.
- High-quality – At AdvancTEK, we are committed to maintaining and enhancing the processes and procedures our customers mandate for their markets. We ensure this by holding certifications such as ISO 9001:2015, IATF 16949:2016, and ISO 14001, which demonstrate our dedication to quality and regulatory compliance.
- Expertise – We have more than 35 years of experience and possess dedicated resources that allow us to deliver solutions that exceed expectations. When you choose to partner with us, know that you’ll have a dedicated team working alongside you from concept to finished production.
Determine the Right Large Part Molding Process for You
Injection Molding Benefits
- Repeatability
- Quick, efficient production
- Material selection flexibility
- Minimal waste
- Design complexity
- Lower piece cost
Recommended for: High Volumes
Reaction Injection Molding (RIM) Benefits
- Large, lightweight parts
- Complete design freedom
- High strength-to-weight ratio
- Excellent thermal stability
- B-side features and insert encapsulation
- Lower tooling investment than injection molding
- Rapid prototyping capabilities
Recommended for: Low to Moderate Volumes
Thermoforming Benefits
- Cost-effective tooling
- Shorter lead times
- Highly customizable
- Endless possibilities for color and texture
Recommended for: Low to Moderate Volumes
Where AdvancTEK Molds Large Parts
AdvancTEK runs large part injection molding at facilities in Concord, North Carolina and Saltillo, Coahuila, Mexico, with headquarters in New Albany, Ohio. Reaction injection molding is performed at both plants. Thermoforming is performed at our Saltillo facility as well as our Dublin, Virginia location.
Our company holds IATF 16949 and ISO 14001 certification and carries ITAR registration. For programs in defense and regulated industrial markets, those registrations determine which molders can be considered at all.
AdvancTEK is a CVG brand, created to deliver custom engineering, value-added services, and production solutions to markets beyond transportation.
Concept to Customer: Optimized Manufacturing Design and Development Services
Design and development are key to success in manufacturing. For several decades, AdvancTEK has guided numerous customers through the development of custom solutions by understanding their visions and expectations. We apply our decades of experience by asking the right questions to assist you in making informed choices for your project. Read our blog to discover more about our design and development services.
Reaction Injection Molding
Are you searching for the right manufacturing process for your lower-volume production? Reaction Injection Molding (RIM) might just be the perfect option if injection molding is too costly for your volume needs and thermoforming can’t meet your design criteria. Read more about the benefits of RIM and our capabilities today.
AdvancTEK’s Guide to Selecting the Right Plastic Manufacturing Process
The overall cost, quality, and efficiency of your products greatly depend on the type of manufacturing process selected. Each process, from injection molding to thermoforming, offers unique advantages for specific applications. From years of industry experience, AdvancTEK has learned the nitty gritty details of each process, making us experts in determining which one is right for any given project. Read our guide for selecting the right plastic manufacturing process to learn more.
Large Tonnage Molding
When molding large parts, several factors should be considered that can significantly impact production efficiency. Press size, material type, and processing parameters for heating and melting the resin are just a few of the key considerations that should be taken into account. These factors can help you narrow down your options for manufacturing partners and make the best choice for your needs. Read our blog to dive deeper into the world of large tonnage molding.
Large Part Injection Molding FAQs
What role does the material play in large part molding projects?
Choosing the right material is vital for project success, as the choice of material can impact the required clamping force and the type of machines that can be used. At AdvancTEK, we have access to a material library to identify resins with superior flow characteristics, which can help fill large parts more efficiently and enhance their aesthetics.
What are some common challenges that I may face in large part molding?
We find that our customers struggle to find suppliers with the capacity to handle large molds. As injection mold tonnage increases, the availability of suppliers or equipment diminishes, therefore driving up costs and timelines. We address this with our robust inventory of large tonnage machines across our facilities in the U.S. and Mexico, guaranteeing we can support projects regardless of the location.
How do you determine the size of the machine that is needed?
There are many factors that play into determining the size of the machine needed such as material type, wall thickness, and gating. Our large part injection molding company conducts a detailed mold flow analysis and simulations to ensure the most efficient use of equipment.
What is the largest tonnage injection molding press AdvancTEK operates?
AdvancTEK currently offers up to 3,500-ton molding and is willing to invest in larger or unique capital equipment to help bring a project to reality. The full press range runs from 65 tons to 3,500 tons across our Concord and Saltillo facilities.
How do I know if injection molding large parts is right for my project?
Injection molding is the right choice for large parts at high volume. The tooling investment is higher than thermoforming, but the price per unit is lower and the process is highly repeatable, so part dimensions stay consistent from run to run. If the design requires features on both the A and B surfaces of the part, injection molding supports that where thermoforming does not.
What if my volume does not justify large part injection molding tooling?
Reaction injection molding is usually the answer at lower volumes. RIM produces large, lightweight parts with a high strength-to-weight ratio at a lower tooling investment than injection molding, and it accommodates design geometry that thermoforming cannot. AdvancTEK molds RIM clamps up to 3 feet by 10 feet. The RIM versus injection molding versus thermoforming comparison walks through the tradeoff in detail.
Contact Our Team Today for Large Part Molding
No matter how complex the project is, we’re here to create a tailor-made solution just for you. If you want to learn more about injection molding large parts and what we can deliver, contact us today. We look forward to hearing from you!