It's a pretty safe assumption that you'd like to save money on your next injection molding project. It's also probably safe to assume that you've been actively trying to do so. Yet with a process as versatile as injection molding ' one that can meet countless needs and be used in so many ways ' there are also many ways to achieve further cost savings, which differ from job to job and application to application.
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What's more, the definition of 'cost savings' can vary depending on where you're looking to reduce costs. Shorter-term cost savings might include cost per part or finishing services on a specific job. Longer-term cost savings can come in areas such as decisions about mold manufacturing, or big-picture adjustments to the design principles that your engineers follow.
With all of that in mind, this piece is intended to provide a little bit of everything, which will hopefully help you get direct results in your next project, or to at least start thinking about your product and mold designs in a different way ' to identify more opportunities for cost savings.
We'll start with a big-picture topic (with which many readers may be at least partly familiar) and move forward from there.
1. Follow injection molding best practices: This is a key tenet of injection molding, and while it may seem obvious, it falls by the wayside all too often. Why? You may hear numerous reasons: a perceived interference with the form or function of the part, a lack of time, or even a lack of knowledge of these best practices. Though the simple fact remains: A part designed in adherence with best practices can be manufactured more quickly, more efficiently, with fewer errors ' all adding up to lower costs. As an introduction (or refresher) to these best practices, here are some factors to consider:
2. Consider volume in the process: Of course, the higher the volume of parts you're producing, the lower your cost per part will be. However, that doesn't help if you only need a run of 20,000 parts ' let alone 1,000, or just one. Shorter runs can also be produced by different methods than those used for long runs ' which can start driving down your cost per part in a big way. If you're in need of a short or medium part run, still want to use a molding process, and don't want to invest in a costly steel mold, using a different mold material can be a big help. Look at silicone molding or neoprene casting, for example.
3. Simplify your design: Fewer part features and geometries ' and greater simplicity ' will always make your part easier and, thus, less costly to manufacture. Take an objective, dispassionate look at the design of your product, and remove any unnecessary features, designs or other aspects that aren't critical to the performance of the part. This can be a difficult process for someone who has worked hard on designing a part a certain way, but can definitely yield cost savings that make it worth it.
4. Eliminate unnecessary production and processes: Overproduction has thrown off many a P&L, often without anyone ever realizing it. In injection molding, that means to make sure you're only using as high-grade a material as required for the part function; that the mold material is in line with your needs and expectations for performance and shelf life; and that you've eliminated as many finishing processes as possible (following design best practices and simplifying your design can help with this). Also consider the aesthetic needs of your part: While the appearance of most injection molding plastics isn't necessarily attractive, it also doesn't need to be for the majority of industrial needs. Eliminate any unnecessary dyes and pigment processes, as well.
5. Look at manufacturing partners for outsourcing: In-house injection molding is costly ' there are no two ways about it. While it may be tempting to incorporate in-house injection molding ' or expand on your existing capacity ' to fulfill additional orders, it's also a huge investment that can take a long time to recoup. Seeking a manufacturing partner for injection molding removes the burden of machine investment (and maintenance, operation, replacement, etc.) from you, and allows you to focus simply on providing a part design and relying on the partner's expertise.
6. Research and choose the right partner: If you've decided to outsource your injection molding, choosing the right partner is another area where costs can be higher or lower, depending on the approach taken. Inexperienced facilities, or those that may have different specialties than what your project requires, can indirectly increase costs. The process may take longer, it may be more prone to misunderstanding or error between the two parties, and the quality may not be up to your expectations. Be sure to research your options extensively. Look for an experienced facility with its expertise on display ' readily available for you. Shops that offer related services can also reduce your costs by incorporating prototyping, design, fulfillment and more into the production process.
With these tips in mind, you're now ready to start identifying ways to lower costs for your injection molding projects ' something you may not have previously thought possible. The lowered costs you can see across the board will make your time and energy investment well worth it.
There are many variables to consider when designing and producing injection-molded plastic parts. A knowledgeable and effective molding partner can help you reach a common-sense solution that helps you to save money ' without sacrificing part quality.
Here is a closer look at four key variables you need to think about when selecting an injection molding partner.
As an OEM, you have many options when it comes to sourcing a mold tool for your project. One common money-saving strategy is to utilize an overseas tooling supplier. The downside of this approach is that it can add a significant amount of lead time and risk to your project.
Poor quality tooling made of inferior steel is a common issue with overseas suppliers. Typically, this compromises the tool's longevity. If you plan to keep a part in production over a long period of time, saving a few dollars on the front end of a project could end up costing you a lot more in the long run. That's why it's imperative to ensure that the overseas mold builders your supplier is working with are high quality and operate with integrity.
Contact us to discuss your requirements of high-speed Bakelite injection moulding machine. Our experienced sales team can help you identify the options that best suit your needs.
Whether you select domestic or overseas tooling, one way to save money is to bundle multiple tools into one package. This should enable you to negotiate a better per-tool price with the toolmaker.
What volume of parts do you plan to produce? If you need a smaller number of parts, you may be able to save money by having your tooling made of aluminum instead of steel.
A common-sense approach to your tooling needs will help you to balance part cost, quality and risk.
Mold design presents a major opportunity to reduce material use. Solid walls in your part designs can be replaced by latticed walls that won't warp and will maintain the structural integrity of the part. This not only helps you save money on material but also speeds processing because thinner walls cool faster than solid ones.
Production volume should be a major consideration in tool design. The annual demand and life of the product should be considered when designing a tool. It's important to ensure that the material used for your mold is matched with the demands that will be placed on it throughout its production life.
Today's additive tool design technology enables toolmakers to vary the density of the tool steel to add strength in key areas that need it. Conformal cooling channels can also be built into additively-designed tools to help them cool faster and speed the production of your parts.
The material you select for your parts can have a significant impact on their cost and quality.
In creating recommendations for our customers, we consider multiple factors, including the application requirements and the processability of the material. Our Design for Manufacturing (DFM) process helps us to identify potential issues with part and mold designs, material selection and molding processes early in the launch process, so we can mitigate or eliminate them.
Working with an injection molder that has engineers on staff with material science backgrounds is a big plus. They can help you select a material that meets all your part's performance requirements but also can be processed efficiently and consistently, with a minimum of tool wear.
Secondary processes such as painting, welding, pad printing and chrome plating can also add significant cost to your parts. To make matters worse, many injection molders don't have well-defined, efficient processes in place to manage secondary processes. This freewheeling approach can lead to cost overruns and quality problems.
During the last several years, New Berlin Plastics has developed a deep level of expertise in secondary processes. We can help you to develop elegant and cost-effective solutions to your finishing needs.
When selecting a plastic injection molder, don't just look for a supplier with relevant technical expertise. Seek one that also consistently applies best-in-class management practices and continuous improvement methodologies to the business of injection molding.
This leadership mindset has deep implications, affecting everything from who it hires, investments in people and technology and the processes it uses to build a stable, responsive, customer-focused business.
That's our focus at New Berlin Plastics, and it's what sets us apart from other plastic injection molders. A great example is our new, proprietary LaunchLogic process, which has enabled us to achieve a 98% on-time launch track record over 100 simultaneous open customer projects. Learn all about it in our new LaunchLogic eGuide.
At New Berlin Plastics, we're continually reinvesting in our business to meet and exceed your expectations. Why not contact us about your next plastic injection molding project?
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