We are A professional supplier for plastic injection molding in China
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!
- quality GUARANTEED
- Lower prices
- easy communication
Type: precision molding
This example of the Lego part shows how to achieve the precision of the injection mold final plastic part. Click to see more details.
Type: precision molding
An injection mold for producing a power tool housing. This example shows the importance of proper gate design. Click to see more.
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: 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: 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.
Having properly defined quality standards is delicate, and we will provide our insights in this area to make your project a success.
Ensured quality
1. Understand the product
Providing details about the product’s use, how plastic parts are assembled and function in the assembly can help us understand the dimensional and aesthetical requirements.
2. Set the inspection criteria
We will create a 2D drawing, specify all necessary dimensional and geometric tolerances (such as flatness, roundness and concentricity), and define the amount of acceptable bending, warping and distortion.
3. DFM and Mold Flow Analysis
We will conduct a DFM and probably a mold flow analysis to see what issues may arise either on the product side or the mold side. Some issues need attention from the mold design stage.
Many molding defects are predictable, and they can be avoided or kept within an acceptable level.
DFM (Design for Manufacturing) is an efficient communication tool between the client and the mold maker in the conceptual design stage. Click the image to find out more…
For more demanding plastic parts or more expensive molds, the mold flow analysis can be performed to evaluate possible molding defects and find better solutions. Click the image to find out more…
Our engineering services
Material selection
Choosing the right material is crucial to the success of a project from the very beginning。
Product design
We don't usually start from scratch, because communication from a distance can be a barrier. We can optimize your design in terms of manufacturability, aestietics, and functionality.
Reverse engineering
In addition to using professional scanning and measuring instruments, it takes experience and talent to replicate a product exactly as the original sample.
Rapid prototyping
Other than photosensitive resins, we can use different materials for rapid prototyping: soft/flexible, transparent, and nylon.
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% |
The processes of mold making
The DFM and Mold flow analysis can help you avoid potential production problems, optimize the part and mold design and shorten the overall production cycle.
This will include deciding the type and location of the injection gates and ejector pins, wall thickness and draft analysis, possible molding defects and solutions, and so forth.
- Mold design requires extensive experience, great care, and it is time-consuming.
- The mold design is a key factor in the success of the mold, as the machining is all based on the drawings.
- It is often a collaboration between the molders and designers to ensure that every detail has been properly arranged.
- This process will usually take 2 to 5 days.
- This usually includes CNC milling, wire and electrode EDM (and the machining of electrodes).
- A heat hardening may be required between the rough and finish machining.
- Different grades of processing equipment are available, and choosing the right equipment can save costs while ensuring quality requirements.
- The machining process typically takes 7 to 15 days.
- Ideally, the molded parts should be manufactured to a very high degree of precision so that the mold can be just assembled and put into use. This is possible, but very costly.
- In common practice, the machined parts are usually polished or modified to make sure the ideal engagement of mating components is obtained.
Small errors and omissions in the design should also be fixed. - The mold assembly process will normally take 5 to 15 days.
- In this phase, we will check if the mold is working as expected, and verify if the T0 samples meet the dimension tolerances, without noticeable flaws, and function properly in their assembly.
- For T0 samples, the surface texture is usually not yet applied and the tool steel is not yet hardened in anticipation of possible tooling corrections or modifications.
- The cycle time from the very beginning of mold production to T1 samples will usually be 25 to 40 days.
- The mold or the T0 samples may have flaws or imperfections that need to be fixed.
- Sometimes the customer will require design changes on the parts.
- After that, T1 samples will be made for inspection.
- The mold modification will normally take 15 to 30 days.
- After the samples are approved and the mold is tested and ready for production, it is time to apply surface textures and harden the tools.
- Some plastic parts have a polished finish or a sanded finish (which can be simply obtained from electrode EDM), so they do not need the texturing process.
- The hard molds (made of steel H13, S136, etc), the steel is hardened before finishing machining, so they do not need any more hardening at this stage.
Now we are good to move forward to deliver the mold or start production!
Customer testimonials
— At Boyan, we are always grateful for the opportunities to face challenges, inspire creativity, and grow alongside our customers’ businesses.
Customer references are available in these countries. If you would like to speak with our customers directly, we can provide you with their phone numbers.
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.
Blog posts
A quick self-estimation of injection mold cost in China
An easy guide to DFM (Design for Manufacturing) in Plastic Injection Molding
Common Injection Molding Defects that Customers Should Know About
