We are A professional supplier for plastic injection molding in China
- Lower prices
- quality GUARANTEED
- easy communication
Boyan Manufacturing Solutions takes pride in supplying high quality plastic injection molds and injection molded parts, together with professional engineering support and customer services. More importantly, we help you to stay within your budget!
Our expertise in plastic injection molding
Our capabilities cover precision injection molding, multi-shot injection molding, insert molding, TPE/TPU over-molding, and more. Below are some examples:
Type: precision molding / 2-shot molding
Lens retainers that used under the back panel of the phones. High precision and uniformity are required.
Type: precision molding
This is a pin connector used on PCBs. High precision and uniformity are required.
Type: precision molding / TPU molding
This is a side seal for mobile phones, with the material TPU. There are small details made to high precision to prevent flashes.
Type: TPE overmolding
This is a handle for power tools. The substrate is ABS with TPE overmolded.
Type: nylon mesh overmolding
This is a square bin with a nylon mesh on the bottom.
Type: clear plastic molding
These are lenses for LED lights. The surface pattern is most critical for the proper projecting of lights. Each part need to have the same weight for cost saving in large volume production.
Type: chrome plating
This is a wide reflective mirror made of ABS, with the surface plated with chrome.
Type: ultrasonic welding
The cup body consists of 2 walls for better heat insulation. The bottom is welded to the cup body. The material for this cup is ABS.
Explore our World Class Capabilities
Our engineering services
We are more than a mold maker: we provide full services to get your job done correctly and within your budget!
Material selection
Choosing the right material is of vital importance for the success of your project from the beginning
Design for Manufacturing
The wall and rib thickness / draft angles / surface finishes / Possible advice on structral modifiction to keep the mold being reasonably simple.
Mold flow analysis
For more demanding plastic parts or more expensive molds, we will perform mold flow analysis to evaluate possible molding flaws and find better solutions.
Reverse engineering
Creating 3D modes, material analysis based on the original samples.
Product design
We usually do not start from scratches, because long-distance communication can be obstructive. We could optimize your design for manufacturability, appearance and functionality.
Rapid prototyping
Available materials for rapid prototyping include: transparent, soft (elastic), and strong and durable materials.
Low prices
We keep our price low and transparent. If you request, we will send you mold cost breakdown so you can see the composition of the mold cost, and you can also check each item is reasonably and correctly calculated.
The below table gives the usual percentage of each cost:
| Item | Percentage | |
|---|---|---|
| 1 | Material | 20-35% |
| 2 | Machining | 25-40% |
| 3 | Assembly | 15-20% |
| 4 | Mold design | 5-10% |
| 5 | Tax, profit | 20-30% |
Having properly defined quality criteria is subtle, we will provide our insight in this regard to make your project a success.
Ensured quality
Understand the product
It is always helpful to explain to us how the plastic part is assembled and functions in its assembly, how it interacts with the mating component.
Set up inspection criteria
We will create a 2D drawing specifying all necessary dimensional and geometrical tolerances (like flatness, roundness, and concentricity), and define the acceptable amount of the bend, distortion, and warpage.
Analysis and avoid possible molding defects
At the same time, we know what possible injection molding defects may arise with your products and will take measures to prevent or minimize the defects.
The processes of mold making
- This is an important process to avoid costly mistakes later on.
- Technical details that need to be verified: number of gates, locations of the gates, eject pins, and parting lines. This is mainly for aesthetic purposes.
- Sometimes a mold flow analysis needs to be conducted to see if there will be molding defects with this design.
- This will usually take 2 to 5 days.
A high level of precision is required for the machining and measuring of the mold components, but not overly high in order to save costs. We will choose the most cost-effective machine tools to do each specific job.
The machining process typically takes 7 to 15 days.
- Some mold components will need to be modified, either by CNC machines or manually to reach optimum tightness of fit and alignment of the top surface (like the sliders, eject pins with the cavity surfaces).
- The movements of the components (sliders, eject pins) need to have certain friction, but with minimum stiffness.
- The mold assembly process will normally take 5 to 10 days.
- With the newly made mold, we will submit you T1 samples for testing and approval.
- The T1 samples may not have the required textures if the texture is a secondly process.
- The cycle time from the very beginning of mold production to T1 samples will usually be 25 to 40 days.
- There could be molding defects or dimensional deviations, or the customer requires to modify the design.
- Try to avoid material additive processes (usually welding) in the mold modifications.
- The mold modification will normally take 15 to 30 days.
- After the T1 or T2 samples have been approved, all details have been checked and verified, we will apply textures. This is optional, sometimes the parts can have a sanded finish (just obtained by EDM) or polished finish, so no secondly texturing is required.
- Many tool steels need to be heat hardened or nitrided for mass production, but tool steel like H-13 and S136 are already hardened so they do not require this process.
- After the T1 or T2 samples have been approved, all details have been checked and verified, we will apply textures. This is optional, sometimes the parts can have a sanded finish (just obtained by EDM) or polished finish, so no secondly texturing is required.
- Many tool steels need to be heat hardened or nitrided for mass production, but tool steel like H-13 and S136 are already hardened so they do not require this process.
Our Happy Customers
Frequently Asked Questions
Do you Provide any kind of Warranty ?
If you find the injection molded parts do not meet the specs or have any quality issues within 3 months of their arrival date, please inform us with pictures indicating those issues. We will send you free replacements at our cost, including possible air freight charges.
What is your MOQ for orders?
There is no MOQ required from us, we take orders from 100 units to 1 million, however, the injection mold itself is kind of expensive. To make your investment worthwhile, we suggest your order quantity should be more than 100, otherwise, you should consider other manufacturing processes.
How do I know I will get the products as I expected?
We will analyze what molding defects may arise before mold production, and take preventive measures.
We will send you detailed QC reports with pictures and videos during production and before shipment, so you know exactly what you will receive prior to shipment.
What is the typical mold life?
A mold can complete from 10,000 shots to 1 million shots, we will choose what mold steel to be used based on your estimation of the quantity. At the same time, if you let us produce the plastic parts, you do not need to worry about the mold life, we will take care of the mold maintenance and renewal, so it is a one-off investment for you.
How do I describe the quality requirements for my products?
It is important that you describe the quality requirements clearly, including the material specs, dimensional tolerances, and visual requirements. If you do not have an engineering background, you can explain to us the application in detail. We will figure it out and list the requirements and specs on a pdf drawing for review. It will be used in manufacturing and QC inspection.