Plastic Injection Molding Services
XC Machining provides plastic injection molding services for US product teams. We mold custom parts in ABS, PC, Nylon, PP, PEEK, TPE, LSR and 50+ thermoplastic and elastomer resins. Presses run from 50 to 800 tons, with tolerances to ±0.05 mm.
All uploads are secure and confidential.
- All uploads are secure and confidential
What Is Plastic Injection Molding?
Plastic injection molding heats thermoplastic pellets to 180°C to 400°C, by material. It injects the melt into a steel or aluminum mold cavity at 500 to 2,000 bar. The plastic fills the cavity, cools and sets into the finished part in a 15 to 60 second cycle.
XC Machining molds parts for automotive interiors, consumer electronics housings, medical device enclosures, industrial equipment covers and packaging. Presses run from 50 tons (small connectors, 5 g parts) to 800 tons (large enclosures, 3 kg+ parts).
Volumes run from 500 prototype units in aluminum rapid tooling to 1,000,000+ parts a year in hardened steel molds with hot runner systems. For the full service range, see our injection molding page.
Key Benefits of Plastic Injection Molding
Benefit | Description |
High efficiency | Cycle times of 15 to 60 seconds per part. A 4-cavity mold makes 5,000 to 7,000 parts in a 24-hour shift |
Design flexibility | Walls from 0.5 mm, living hinges, snap fits, undercuts with lifters or slides, and internal ribs, all in one shot |
Cost-effectiveness | Part cost drops 40% to 70% above 5,000 units compared with CNC machining, as the mold cost spreads out |
Material variety | 50+ resins: commodity (ABS, PP, PE, PS), engineering (PC, Nylon, PBT, POM), high-performance (PEEK, PEI, PPS) and elastomers (TPE, TPU, LSR) |
Precision and consistency | ±0.05 mm standard tolerance, with ±0.005 mm part-to-part repeatability over runs of 10,000+ parts |
Reduced waste | Cold runner regrind recycles 15% to 25% of material. Hot runners remove runner waste and reach 98%+ material use |
Automation | Robotic part removal, automated stacking and in-line vision inspection cut labor to 1 operator per 4 to 6 presses |
Enhanced strength | Glass fiber (10% to 40%), carbon fiber, mineral fillers and impact modifiers add strength, stiffness and heat resistance |
Scalability | Aluminum rapid molds make 500 to 10,000 parts. Steel production molds rated 100,000 to 1,000,000+ shots scale to any volume |
Speed of production | Mold to market in 3 to 5 weeks: a 15-day aluminum mold plus 5 to 10 days of production. Steel production tooling takes 25 to 35 days |
Surface finish | SPI A-1 mirror (Ra 0.012 μm) through D-3 textured (Ra 3.2 μm) straight from the mold, plus Mold-Tech and VDI textures |
Low labor | One operator monitors 4 to 6 automated presses. Parts eject, stack and gate-trim automatically, for 2 to 5 seconds of labor per part |
Sustainability | Closed-loop regrind of TPE, PP and ABS runners. Bio-based PLA and recycled PET (rPET) are available |
Customization | Pantone and RAL color matching, in-mold labeling (IML), in-mold decoration (IMD), two-shot molding and custom textures |
Why Choose XC for Molded Plastic Parts
XC Machining runs plastic injection molding from start to finish. The steps are DFM review, Moldflow simulation, in-house mold design and build, T1 sample trials and production. Presses run from 50 to 800 tons under ISO 9001:2015 quality procedures.
Presses run from 50 tons (connectors, buttons and caps of 1 to 10 g) to 800 tons. Large presses make housings, panels and enclosures of 500 g to 3 kg+. All presses use servo-hydraulic drives for energy efficiency and precise pressure control.
Commodity resins are ABS, PP, PE, PS and PVC. Engineering resins are PC, Nylon 6/66, PBT, POM and PMMA. High-performance resins are PEEK, PEI (Ultem), PPS and LCP. Elastomers are TPE, TPU and LSR. Glass-filled, carbon-filled, flame-retardant and medical-grade compounds are available for engineering resins.
Every project gets Moldflow simulation. It checks fill pattern, weld line location, air traps, cooling uniformity, warpage and gate location. The DFM report and Moldflow results arrive within 48 hours of CAD upload. Our injection mold tooling page covers the mold build.
Cavity finishes follow SPI. A-1 diamond polish (Ra 0.012 μm) is optical. B-1 semi-gloss is Ra 0.05 μm. C-1 matte is Ra 0.35 μm. D-1 textured is Ra 0.8 μm. Mold-Tech and VDI textures suit branded surfaces.
Plastic Parts We Mold
Our plastic injection molded parts include consumer electronics housings, automotive interior panels, medical device enclosures, industrial equipment covers, packaging components and precision connectors. The live gallery shows real injection molded production parts.
Plastic Injection Molding Timeline, File to Parts
A new part moves through the steps below. Times come from XC’s tooling process, and the total depends on mold class.
Step | What happens | Time |
1. DFM and Moldflow | Review of fill, weld lines, warpage and gates | 48 hours |
2. Mold design | 3D CAD of gate, runner, cooling and ejection | 3 to 5 days |
3. Mold machining | CNC cutting of core and cavity | 5 to 15 days |
4. EDM | Wire and sinker EDM for details and textures | 2 to 5 days |
5. Finishing | SPI polishing or texture | 1 to 3 days |
6. Assembly and T1 trial | Fit, trial and sample parts for approval | 1 to 2 days |
7. Production | Parts ship per batch after mold approval | 5 to 10 business days |
Steps 1 to 6 total 15 to 35 days. For quantities below 500, a CNC machined or vacuum cast prototype can cost less than a mold.
Plastic Resins We Mold
XC Machining molds 50+ thermoplastic resins, engineering polymers and elastomers. Each entry gives shrinkage, melt temperature and typical use, so you can shortlist a resin. Glass-filled, carbon-filled and flame-retardant (UL 94 V-0) options are available for engineering resins. Our materials page lists the wider range.
Grades: general-purpose, high-impact, flame-retardant (UL 94 V-0) and medical-grade ABS. Shrinkage: 0.4% to 0.7%. Melt temperature: 220°C to 260°C. Uses: electronics housings, automotive trim, appliance panels and medical device covers.
Grades: PA6, PA66, PA6 GF30 (30% glass-filled) and PA66 GF50 (50% glass-filled). Shrinkage: 0.8% to 2.0% unfilled, 0.3% to 0.8% glass-filled. Melt temperature: 230°C to 290°C. Uses: structural automotive connectors, gear housings, industrial brackets and cable ties.
Grades: homopolymer, copolymer, random copolymer, glass-filled and talc-filled PP. Shrinkage: 1.0% to 2.5%. Melt temperature: 200°C to 260°C. Uses: packaging containers, automotive battery covers, medical disposables and food-contact housings.
Grades: homopolymer (Delrin), copolymer and glass-filled POM. Shrinkage: 1.8% to 2.5%. Melt temperature: 190°C to 210°C. Uses: gears, bearings, conveyor parts, fuel system parts and snap-fit mechanisms.
Grades: LDPE, HDPE, LLDPE and UHMWPE. Shrinkage: 1.5% to 3.5%. Melt temperature: 160°C to 260°C. Uses: packaging, chemical-resistant containers, food-grade parts and low-friction wear parts.
Grades: TPE (Shore A 20 to 90), TPU (Shore A 60 to 95) and LSR (Shore A 10 to 70). Shrinkage: 0.5% to 2.0%. Melt temperature: 180°C to 230°C for TPE and TPU. LSR injects at room temperature and cures at 150°C to 200°C. Uses: soft-touch grips, seals, gaskets, medical silicone parts and overmold layers.
Grades: general-purpose, optical-grade (92% light transmittance), flame-retardant (UL 94 V-0) and medical-grade PC. Shrinkage: 0.5% to 0.7%. Melt temperature: 280°C to 320°C. Uses: transparent lenses, LED diffusers, flame-retardant electrical enclosures and medical device housings.
Grades: PET (crystalline), PETG (glycol-modified, amorphous) and HCPET (high-crystallinity). Shrinkage: 0.2% to 0.5% for PETG, 1.5% to 2.5% for PET. Melt temperature: 260°C to 290°C. Uses: bottles, food-contact packaging, transparent displays and recycled-content (rPET) packaging.
Surface Finishes for Molded Plastic Parts
The mold cavity finish sets the part surface, and post-molding treatments add more. XC Machining offers SPI finishes A-1 through D-3 plus cosmetic and functional treatments. Our surface finishing page lists related options.
diamond-buffed cavities give optical clarity on PC, PMMA and clear resins. Uses include lenses, light pipes, display covers and cosmetic electronics.
stone-polished cavities give a smooth finish. Uses include industrial parts, medical housings and non-optical consumer products.
stone-finished cavities give a uniform matte surface that hides minor sink marks and flow lines. It is common on automotive interior panels and equipment covers.
sandblasted cavities give grip and cosmetic texture. Add 1.5° of draft for each 0.025 mm of texture depth so parts release.
chemical etching or EDM texturing gives leather grain (Mold-Tech MT-11010), stipple, wood grain or branded patterns.
ink transfer for logos, text, icons and multi-color graphics on ABS, PC, PP and Nylon, with Pantone matching.
primer and topcoat in RAL or Pantone colors, soft-touch coatings, UV-resistant clear coats and EMI shielding paints.
permanent serial numbers, logos, QR codes and regulatory symbols with no ink. The laser carbonizes or foams the surface.
pre-printed film goes into the cavity and bonds to the melt. The part comes out decorated in one step.
Our Plastic Injection Molding Prototype Manufacturing Capabilities
Provides injection molding for prototypes and custom parts, emphasizing expert support, competitive pricing, and faster production cycles.
Get reliable vacuum casting services for high-quality prototypes and production parts at competitive prices. XC Machining offers highly detailed casting parts with consistent quality.
Uses cutting, bending, and forming techniques to produce precision metal components suited for industrial, commercial, and manufacturing applications.
Engineering Plastics for Injection Molding
XC Machining molds engineering thermoplastics such as ABS, Nylon, Polycarbonate, POM and PEEK. They differ in strength, impact resistance, size stability and heat performance. Product design, process needs, volume and use decide the material.
ABS has impact resistance, stable size and an attractive surface. It suits high-volume electronic housings, automotive interior parts, consumer products, covers and enclosures.
Nylon is strong and durable, with wear resistance, toughness and fatigue performance. It suits gears, clips, brackets, automotive connectors and mechanical parts that need long-term performance.
Polycarbonate is a high-impact plastic with toughness, stable size and, in suitable grades, optical clarity. It suits transparent covers, protective housings, electrical enclosures, equipment panels and precision industrial parts.
POM has stable size, low friction and wear resistance. It suits gears, bearings, clips, fasteners, sliding mechanisms and parts that need accurate size and steady performance.
PEEK offers heat resistance, chemical stability and strength. Specialized molding processes make PEEK parts for aerospace equipment, medical devices, electrical insulation and high-temperature industrial use.
PTFE has exceptional chemical resistance, low friction and thermal stability. It makes seals, gaskets, valve seats and insulating parts. Standard PTFE needs compression molding and sintering, not conventional injection molding.
Specialist Industries
Bring Your Designs to Life with XC Machining
Experience precision engineering with XC Machining. From detailed prototypes to high-volume production, we’re here to turn your concepts into reality. Contact us today to discuss your project needs!
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Plastic Injection Molding FAQs
What processing technology does XC Machining use?
Our presses use servo-hydraulic drives for ±0.5% shot weight repeatability. Closed-loop barrel control holds ±1°C across 4 to 6 heating zones. Cavity pressure transducers tune pack and hold in real time. Robots remove parts, and in-line vision checks them. Presses run from 50 to 800 tons with shot weights from 1 g to 3,000 g.
How does XC Machining maintain molds for steady quality?
We follow a documented schedule. We clean and lubricate every 5,000 to 10,000 shots and inspect cavities for wear and corrosion after each run. We also check ejector pins and slides, flush cooling channels to stop scale and inspect parting lines for flash. Every task is logged against the mold’s shot count.
How does XC Machining handle complex part geometry?
Moldflow checks fill and weld lines before the mold is cut. Lifters and slides form undercuts and inner features with no second operation. Conformal cooling holds mold temperature within ±2°C on complex shapes. Sequential valve gating controls fill on large parts. Gas-assist injection makes hollow sections in thick parts without sink marks.
What cycle times does XC Machining achieve?
Thin-wall parts (0.5 to 1.0 mm) cycle in 10 to 20 seconds. Standard parts (1.5 to 2.5 mm) take 20 to 45 seconds. Thick-wall parts (3.0 to 4.0 mm) take 45 to 90 seconds. Conformal cooling cuts cooling time 20% to 40%, tuned gates cut fill time, and robots save 3 to 5 seconds per cycle.
How does XC Machining scale production volume?
Three tooling tiers cover volume. Aluminum rapid molds ship in 15 days and run 5,000 to 10,000 shots for validation. P20 bridge molds ship in 20 days and run 100,000+ shots for launch. H13 or S136 production molds ship in 25 to 35 days and run 500,000 to 1,000,000+ shots. Multi-cavity molds of 2 to 64 cavities multiply output.
What makes XC Machining different from other molding suppliers?
We offer three things. We design molds, cut tooling by CNC and EDM, and mold on our own presses, so no handoff between mold maker and molder adds risk. We CNC machine prototypes in the final resin to check a design before tooling. We also mold high-performance resins such as PEEK at 400°C, PEI (Ultem) and PPS.
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