Manufacturers produce large and oversized components using large-part injection molding. Also called large-tonnage injection molding, this technique produces goods for automobiles, industrial systems, medical equipment, and more. While the parts are much larger—requiring bigger, heavy-duty presses—the details are as important as in conventional small-part injection molding. Manufacturers must consider every detail of the mold design to avoid exaggerating errors like uneven textures, gate blush, and weld lines. Initial lead times for large-part injection molding will also be longer, since it takes more time to shape larger blocks of steel into molds.
Learn more about the common applications of large-part injection molding, how the process differs from general injection molding, and how to get the best results by working with the right molding partner.
Automotive
The automotive industry uses both large-part injection molding and small-part injection molding to quickly create tens of thousands of robust, virtually identical vehicle components. Examples of large parts include:
- Bumpers
- Door panels
- Fenders
- Floor rails
- Grilles
- Lamp housings
- Splash guards
These parts must adhere to very high standards of quality so that the entire vehicle meets safety requirements and earns consumer trust. Injection molded plastic parts are already starting to replace small metal components, so large-part injection molding will continue to help make vehicles lighter and more fuel-efficient.
Some of the most popular plastics that large-part injection molding manufacturers use are:
- Acrylonitrile butadiene styrene (ABS)
- Nylon
- Polycarbonate
- Polyethylene
- Polypropylene
Industrial
Manufacturers are also using large-part injection molding to transition complex, expensive metal components in industrial machinery to lightweight, durable plastic parts. Some of the most common applications for large-tonnage injection molding in this industry include:
- Automated processing equipment
- Conveyor systems
- Distribution systems
- Enclosures
- Fan turbines
- Large housings
- Panels
Large-part injection molding processes are compatible with food-safe plastics, UV-resistant thermoplastics, specialty plastics, and other materials needed to meet industrial requirements. Designers can also take advantage of the unique characteristics of some plastics to redesign existing equipment, create innovative new assemblies, and reduce energy consumption through reduced equipment weight.
Medical
The medical industry needs precision products and materials that are safe for human contact and can withstand repeated cleaning cycles. Injection molding is currently a popular choice for meeting these needs, producing small medical goods like wearables, handheld tools, and devices. Plastic injection molding large parts can produce bigger medical components for even more applications, such as:
- Diagnostic equipment
- Hospital beds
- Imaging systems and enclosures
- MRI equipment
- Patient monitors
- Radiation therapy equipment
Injection molding produces large volumes of identical parts that fall within extremely tight tolerances, making standardization simple. Hospitals, urgent care centers, and other healthcare facilities can follow standard procedures regarding equipment maintenance and cleaning, as medical-grade plastics are designed to withstand multiple sterilization cycles without degrading.
Large-Part Injection Molding From Lerner Molded Plastics
Large-part injection molding processes are transforming how industries produce products, assemblies, and equipment. At Lerner Molded Plastics, we offer high-quality injection molding services, including custom large-part injection molding with shot sizes going up to 600 ounces each. As a leading Ohio-based plastics manufacturer, we operate a state-of-the-art, ISO 9001:2015-certified facility housing molding equipment that can fill up to 64 cavities at once and create up to 3,000 tons of force.
Our comprehensive injection molding services include:
- Tooling design and build
- Blow molding
- Large-part rotational molding
- Custom coloring
- Thermoforming
Contact us today to learn more about our services, or request a quote to start your project.