Custom Plastic Injection Molding
XDL Machinery specializes in high-quality, precision-molded plastic components tailored to customer needs. Using advanced technology, engineering expertise, and cost-effective solutions, we ensure fast turnaround, superior quality, and competitive pricing. Whether for prototyping or high-volume production, our ISO and IATF-certified processes deliver reliable results, making us your trusted partner for custom injection molding.
Key Capabilities
1. Innovative Material Solutions for Cost and Performance Optimization
- Diverse material selection: We offer a wide selection of high-performance plastics, tailored to meet the specific requirements of your projects. Our material portfolio includes engineering-grade options such as ABS, PE, PP, Nylon, PC, and more. Each material is carefully chosen for its essential properties—strength, durability, heat resistance, flexibility, and chemical stability—ensuring long-lasting performance and reliability.
- More suitable Material Alternatives: We understand that the materials traditionally used in your projects may not always provide the best balance of performance and cost. Leveraging our extensive expertise, we recommend advanced material alternatives that deliver superior results at a more competitive cost.
- Experimental Validation: We also offer experimental validation to ensure these alternatives meet your precise needs.
For a list of common materials we use, please refer to our Material Section.
2. Material Testing
We conduct comprehensive material testing to ensure the selected plastic meets functional and regulatory standards. Our tests include abrasion resistance, melt index, impact strength, hardness, environmental stress-crack resistance (ESCR), density, and more. If you have specific testing requirements, we can accommodate those as well. In addition to these standard tests, we are fully equipped to accommodate any specific testing requirements you may have. For enhanced assurance, we also offer third-party testing services and can provide official reports for all tests conducted.
Refer to Material Testing for detailed explanation of each test.
3. Quality Assurance and Certifications
Quality is the foundation of everything we do. Our plastic injection molding processes are certified under ISO 9001 and IATF 16949, demonstrating our commitment to maintaining high standards and continuous improvement. From material selection to final inspection, we adhere to rigorous quality control measures to ensure every part meets customer specifications and industry standards.
We employ advanced measurement tools and comprehensive testing protocols throughout the production process, guaranteeing precision, reliability, and consistency in each molded component. Whether it’s prototype production or large-scale manufacturing, our processes are designed to meet the highest quality standards.
For more information about our quality practices and certifications, please visit our Quality Assurance section.
4. Advanced Precision Molding Technology
Equipped with state-of-the-art, fully automated injection molding machines, we deliver intricate and detailed plastic components with exceptional precision. Our automated processes ensure enhanced efficiency, reduced lead times, and consistent product quality across all production runs. By minimizing manual intervention, we achieve tighter tolerances and complex geometries with unmatched accuracy, while also reducing the risk of human error. This automation not only improves cost-effectiveness but also allows for scalable production, ensuring your projects meet the highest standards, regardless of volume.
5. High-Volume and Low-Volume Production
We offer flexibility in production volume to meet the specific needs of your project. Whether you require large-scale manufacturing or low-volume production, our facilities are designed for both. Our advanced processes ensure efficiency and cost-effectiveness across all scales. For high-volume runs, we deliver consistent quality and fast turnaround times, while our specialized teams are equipped to handle small production runs and prototypes, offering customized solutions that match your project’s requirements.
6. Custom Mold Design and Prototyping
Our engineering team provides custom mold design and prototyping, ensuring your requirements are met. We begin the process with a comprehensive Design for Manufacturability (DFM) analysis, which includes Mold Flow Analysis to predict and resolve potential issues before production begins.
We pride ourselves on fast turnaround times, typically ranging from 15 days to 2 months, depending on the complexity and size of the product. Our advanced CNC machining, wire EDM, and spark erosion technologies ensure that we maintain high precision throughout the mold manufacturing process, delivering parts that meet your specifications with exceptional accuracy.
The lifespan of our molds is designed for high durability, with most molds capable of exceeding 500,000 cycles depending on the material used. This guarantees that your production runs will be efficient and reliable.
7. Secondary Molding Processes
we provide a range of secondary molding processes to further enhance the functionality and performance of your injection-molded parts. Our capabilities include:
- Overmolding: Combining two or more materials into a single part for enhanced performance, aesthetics, or durability.
- Insert Molding: Integrating metal or other components directly into plastic parts to add strength, electrical conductivity, or other functionalities.
- Assembly: Full product assembly, including fastening, welding, or other post-molding operations.
8. Various Finish Options
We offer a wide range of finish options to meet the aesthetic, functional, and branding needs of your parts. Whether you need textured surfaces, high-gloss finishes, color matching, or custom branding, we can deliver precise and visually appealing results. Our finishing capabilities include:
- Pad Printing: Ideal for small, intricate designs or logos on curved surfaces.
- Silk Screen Printing: Perfect for high-quality, durable graphics and designs on flat or cylindrical parts.
- In-Mold Labeling (IML): Enables permanent, high-quality graphics directly integrated into the part during the molding process.
- Surface Coatings: Offering a variety of coatings for enhanced protection, aesthetics, and resistance to wear.
9. Multi-Cavity and Family Molds
We offer efficient, high-volume production solutions through the use of multi-cavity molds, which allow for the simultaneous production of multiple identical parts in a single cycle, increasing productivity and reducing per-unit costs. Additionally, our family molds enable the production of multiple part types in a single molding cycle, optimizing manufacturing time and costs while ensuring consistent quality across different components.
10. Part Size Flexibility
We provide exceptional flexibility in part size and complexity, accommodating a wide range of customer needs. Whether you require small, precision components weighing as little as 1 gram, or large, structural parts weighing several kilograms, our capabilities ensure high-quality production across all sizes. We can also handle parts with dimensions up to 1,000 x 700 x 700 mm, making us well-equipped to meet diverse project requirements and specifications.
11. Material Analysis and Reverse Engineering
We understand that some projects may begin with only a sample part, lacking detailed blueprints or material specifications. For these cases, we offer comprehensive material analysis and reverse engineering services to bring your ideas to life. Our experts analyze the material composition of your sample and reverse-engineer the part to create precise CAD drawings and specifications. This ensures we can replicate the functionality, aesthetics, and performance of your original product, even without the initial design documentation. Whether you need assistance with material identification, part redesign, or prototype development, we are fully equipped to guide you through the entire process, ensuring accuracy and quality every step of the way.
12. Commitment to Sustainability
At XDL Machinery, we are deeply committed to sustainable manufacturing practices that minimize environmental impact while ensuring the highest quality products. We prioritize the use of recyclable materials in our production processes and have made the conscious decision to avoid non-recyclable materials such as thermosets and bakelite. This not only helps reduce waste but also ensures that our products are environmentally friendly and aligned with global sustainability standards.
Our production facilities also maintain a clean and safe environment by eliminating common industrial pollutants such as dust and noise pollution, and we take proactive measures to manage waste disposal, including the safe handling and discharge of wastewater and waste oil. By implementing these eco-friendly practices, we strive to reduce our carbon footprint and promote a healthier environment for both our employees and the communities we serve.
General Process for manufacturing Plastic Injection Molding parts
1. Raw material examinations
2. Resins mixing
3. Injection
4. In-progress inspection
5. Labeling
6. Pre-delivery Inspection
7. Packaging
8. Delivery
gallery of our injection molding parts
Quality Assurance
At XDL Machinery, quality is at the heart of everything we do. We ensure that each plastic injection-molded component undergoes rigorous inspections and precise testing at every stage of production. Our dedication to excellence guarantees that all products meet your exact specifications and industry standards, delivering reliable, high-quality results. Our key quality assurance procedures include:
1. Material testing
We work exclusively with trusted suppliers to ensure the quality of the raw materials used in your products. All materials are thoroughly inspected upon arrival to ensure they meet stringent specifications and are free from defects. Our material testing procedures include:
- Abrasion Resistance: Assesses the material’s ability to resist wear and tear under repetitive motion or friction, ensuring longevity in demanding applications.
- Melt Flow Index (MFI): Measures the flow characteristics of plastics under high load and temperature, indicating how the material will behave during the injection molding process.
- Impact Strength: Determines the material’s ability to withstand sudden forces or impacts without fracturing, ensuring durability in real-world conditions.
- Hardness: Evaluates the material’s resistance to indentation or surface deformation, providing insights into its suitability for different functional requirements.
- Environmental Stress-Crack Resistance (ESCR): Tests the material’s ability to endure stress and exposure to harsh environmental conditions, critical for parts used in challenging environments.
- Density: Verifies the material’s mass per unit volume, confirming its strength, weight, and suitability for specific applications.
2. In-Process Inspection
We maintain rigorous quality control throughout the entire production process. Each production batch undergoes regular in-progress inspections to ensure both critical dimensions and appearance are up to the highest standards, ensuring consistent, defect-free parts.
Critical Dimensions: We closely monitor key tolerances and measurements to confirm that all components fit perfectly into the final assembly.
Appearance: We inspect each part for visual defects such as scratches, discoloration, burrs, and any inconsistencies.
3. Pre-delivery Inspection
Before any batch is approved for shipment, we conduct thorough final inspections to detect dimensional deviations, ensuring that all parts comply with customer requirements and standards. We utilize advanced measuring tools, such as Vision Measuring Systems (VMS) and Coordinate Measuring Machines (CMM), to verify precise dimensions and tolerances.
4. Functionality Testing and Reliability Analysis
For parts that require functionality testing, we design and build custom test equipment to simulate actual working environments. This allows us to conduct lifecycle testing and other performance assessments as needed. We carefully analyze the test results and provide our customers with reliable data, helping them make informed decisions and ensuring the performance and durability of the final product.
5. First Article Inspection (FAI)
We conduct First Article Inspections (FAI) for initial production runs to verify that molded parts meet all specifications and quality standards before mass production begins. This thorough inspection process allows us to identify and address any necessary adjustments early, minimizing the risk of defects and ensuring consistent product quality throughout production.
6. Traceability and Documentation
We prioritize transparency and accountability through comprehensive traceability and documentation for all plastic injection molded parts. Our quality management system is designed to provide customers with detailed records, ensuring the highest level of consistency and reliability in our products. The major quality-related documents we provide include:
Mill Certificate
Inspection Report
Production Part Approval Process (PPAP)
Statistical Process Control (SPC) Charts
Control Plans
Process Flow Diagram
7. Third-Party Testing and Certification Support
If additional validation is required, we partner with accredited third-party laboratories to conduct specialized testing, including CMM testing, and provide official certifications. This service is especially beneficial for projects that need to meet specific industry regulations or standards, ensuring that your products comply with all necessary guidelines.
8. Continuous Improvement
We are dedicated to the ongoing enhancement of our processes and capabilities. By utilizing data from our quality control systems and incorporating customer feedback, we continuously optimize efficiency, reduce defects, and strive to deliver the highest level of customer satisfaction.
Commonly Used Materials in Injection Molding
We offer a wide selection of thermoplastic materials to suit your specific requirements. From high-strength engineering plastics to biodegradable options, we have you covered.
General Purpose Plastics
Description
Polyethylene (PE) is one of the most commonly used thermoplastic polymers, renowned for its cost-effectiveness, ease of processing, and versatility. It is a lightweight and durable material that offers excellent chemical resistance and is suitable for a broad range of applications. Polyethylene can be processed through injection molding at relatively low temperatures, making it ideal for high-volume production. Available in high-density polyethylene (HDPE) and low-density polyethylene (LDPE), the material can be tailored for different needs based on strength, flexibility, and processing ease.
Properties
- Chemical Resistance: Outstanding resistance to a wide range of chemicals, including acids, bases, and solvents, which makes it ideal for use in containers, piping, and chemical tanks.
- Impact Resistance: Offers good impact resistance, especially in its HDPE form, making it perfect for products exposed to physical stress or outdoor conditions.
- UV Resistance: UV-stabilized polyethylene (or UV-resistant PE) is ideal for outdoor applications, as it is resistant to degradation caused by ultraviolet radiation, preventing brittleness or fading over time.
- Electrical Insulation: Polyethylene has excellent electrical insulating properties, which makes it a preferred material for wiring insulation, cables, and electrical housings.
Common Applications
- Packaging (bottles, films, containers, and plastic bags)
- Automotive (fuel tanks, interior panels, and bumpers)
- Consumer Products (toys, home appliances, and household items)
- Piping (pipes and fittings for plumbing, irrigation, and chemical transfer systems)
Description
Polypropylene (PP) is a thermoplastic polymer known for its high strength, low density, and chemical resistance. It is widely used in injection molding due to its ease of processing, durability, and ability to be customized for different applications. PP is resistant to many chemicals, moisture, and heat, making it suitable for a variety of industrial, commercial, and consumer products. Available in various grades, including homopolymer and copolymer, PP can be tailored for applications that require rigidity, flexibility, or enhanced impact resistance.
Properties
- Chemical Resistance: Excellent resistance to acids, alkalis, and solvents, which makes it ideal for use in containers, chemical tanks, and laboratory equipment.
- Impact Resistance: High impact resistance, particularly in copolymer form, making it suitable for parts that will undergo physical stress or handling.
- UV Resistance: UV-stabilized PP is available, providing protection against degradation from ultraviolet rays, which is essential for outdoor and weather-exposed applications.
- Thermal Resistance: Good resistance to heat, with a higher melting point (160–170°C), allowing it to be used in high-temperature applications without deforming or losing its properties.
Common Applications
- Packaging (containers, bottles, food packaging, and caps)
- Automotive (bumpers, interior panels, and under-the-hood parts)
- Consumer Goods (household items, furniture, and toys)
- Medical Devices (surgical trays, diagnostic equipment, and medical containers)
Description
Polystyrene (PS) is a versatile, cost-effective thermoplastic polymer commonly used in injection molding for a wide range of applications. Known for its rigidity, clarity, and ease of processing, PS is often used in the production of transparent products or components that require high dimensional stability. It is typically found in general-purpose (GPPS) or high-impact (HIPS) grades, with the latter offering enhanced toughness and impact resistance. PS is often chosen for low-cost, mass-produced items due to its ability to be molded into complex shapes easily.
Properties
- Chemical Resistance: Moderate resistance to chemicals and solvents, making it suitable for many consumer goods and packaging applications, but less ideal for harsh industrial environments.
- Impact Resistance: HIPS (High Impact Polystyrene) offers excellent impact resistance, making it suitable for products that need to withstand physical handling and stress.
- UV Resistance: Polystyrene is not naturally UV-resistant, but UV-stabilized versions can be used for applications exposed to sunlight or weather. Without UV stabilization, it can become brittle and degrade over time when exposed to UV rays.
- Transparency: Polystyrene offers excellent clarity, making it ideal for applications requiring clear or transparent parts such as displays, signage, and protective covers.
Common Applications
- Packaging (food containers, disposable cutlery, and blister packs)
- Consumer Goods (household items, toys, and disposable products)
- Medical (protective packaging, laboratory ware)
- Electronics (enclosures, electrical housings, and parts)
Description
Polyvinyl Chloride (PVC) is a widely used thermoplastic polymer that offers excellent durability, chemical resistance, and cost-effectiveness. In injection molding, PVC is often chosen for applications requiring strong, tough, and weather-resistant parts. It is available in two main forms: rigid PVC (uPVC), used for pipes, profiles, and fittings, and flexible PVC, which contains plasticizers and is used for softer applications like wiring, hoses, and medical devices. PVC is easy to process and can be customized with additives for specific properties, such as UV resistance or flame retardancy.
Properties
- Chemical Resistance: Excellent resistance to acids, bases, and salts, making it suitable for pipes, chemical tanks, and industrial applications.
- Impact Resistance: Good impact resistance, especially in rigid PVC, although flexible PVC offers enhanced impact resistance for applications that require greater flexibility.
- UV Resistance: UV-stabilized PVC is available for outdoor applications, as unmodified PVC tends to degrade under prolonged UV exposure. UV stabilization prevents brittleness and discoloration.
- Electrical Insulation: PVC is widely used for electrical insulation, particularly in cables, wires, and connectors, due to its excellent insulating properties.
Common Applications
- Pipes and Fittings (plumbing, irrigation, and drainage systems)
- Window and Door Profiles (construction, building materials)
- Medical Devices (tubing, blood bags, and IV components)
- Electrical Insulation (cables, wiring, and connectors)
- Packaging (containers, bottles, and blister packs)
Engineering Plastics
Description
Acrylonitrile-Butadiene-Styrene (ABS) is a widely used thermoplastic polymer known for its strength, rigidity, and impact resistance. ABS is made by polymerizing acrylonitrile, butadiene, and styrene monomers, resulting in a material that balances toughness and ease of processing. It is a popular choice in injection molding for producing high-quality, durable parts with excellent surface finish. ABS can be easily molded into intricate shapes and is often used for products that require both aesthetic appeal and structural integrity.
Properties
- Impact Resistance: Excellent impact strength, making it suitable for parts exposed to frequent handling, drops, or shocks, such as housing and protective covers.
- Chemical Resistance: Good resistance to mild acids, bases, oils, and greases, though it is susceptible to certain solvents like acetone and alcohol.
- Thermal Resistance: Moderate heat resistance, with a higher heat deflection temperature than many other plastics, making it suitable for parts exposed to higher temperatures (up to 100°C/212°F).
- Aesthetic Qualities: ABS has excellent surface finish, allowing it to be used in applications where appearance is important, such as consumer electronics and automotive trim. It can also be easily painted and decorated.
Common Applications
- Consumer Electronics (TV casings, laptop housings, mobile phone cases)
- Automotive Parts (bumpers, dashboard components, trim pieces)
- Toys (Lego bricks, action figures, and playsets)
- Appliances (refrigerators, washing machine parts, and vacuum cleaner housings)
- Industrial Equipment (tools, connectors, and valve bodies)
PC (Polycarbonate)
Description
Polycarbonate (PC) is a high-performance thermoplastic known for its strength, transparency, and heat resistance. It is often used in injection molding for producing parts that require high impact resistance and optical clarity. PC is inherently tough and can withstand high temperatures without losing its mechanical properties. Its transparent nature makes it an excellent choice for optical lenses, protective covers, and lighting components. PC can be easily molded into complex shapes and is used extensively in both consumer electronics and industrial applications.
Properties
- Impact Resistance: Extremely high impact resistance, even at low temperatures, making it ideal for applications that require strong, durable materials, such as protective covers and safety equipment.
- Transparency: Excellent optical clarity, often used as a substitute for glass in applications that require transparent parts, such as lenses, windows, and light covers.
- Heat Resistance: High heat deflection temperature (up to 135°C/275°F), allowing PC to maintain its mechanical properties under elevated temperatures, making it suitable for electrical enclosures and automotive parts.
- Electrical Insulation: PC has good electrical insulating properties, making it ideal for electrical housings, connectors, and components used in electronics and power systems.
Common Applications
- Consumer Electronics (smartphone screens, laptop housings, light fixtures)
- Automotive (headlamp lenses, dashboards, interior panels)
- Optical Products (glasses lenses, safety goggles, protective covers)
- Electrical Components (connectors, switchgear, housings for electrical equipment)
- Industrial Equipment (machine guards, enclosures, impact-resistant covers)
PC+ABS (Polycarbonate + Acrylonitrile Butadiene Styrene)
Description
PC+ABS (Polycarbonate + Acrylonitrile Butadiene Styrene) is a blended thermoplastic that combines the best qualities of polycarbonate (PC) and ABS. This alloy offers enhanced impact resistance, strength, and heat resistance, while maintaining the ease of processing and aesthetic properties of ABS. The combination of PC’s high toughness and optical clarity with ABS’s rigidity and surface finish results in a versatile material used in demanding injection molding applications. PC+ABS is commonly used in industries where durability and appearance are both important, such as in consumer electronics and automotive components.
Properties
- Impact Resistance: Excellent impact resistance, providing superior toughness compared to pure ABS, making it ideal for parts that need to withstand physical stress and rough handling.
- Heat Resistance: Enhanced heat resistance compared to standard ABS, with a higher heat deflection temperature, making it suitable for applications exposed to higher temperatures.
- Surface Quality: Good surface finish and the ability to be painted or decorated, making it suitable for aesthetic applications such as consumer electronics housings and automotive trim.
- Chemical Resistance: Improved chemical resistance compared to pure polycarbonate, making it suitable for environments with exposure to mild chemicals, oils, and greases.
Common Applications
- Consumer Electronics (smartphone housings, tablet covers, laptop shells)
- Automotive (exterior parts, trim, dashboard components, center consoles)
- Medical Devices (enclosures for medical instruments, diagnostic equipment)
- Industrial Equipment (machinery parts, enclosures for electrical equipment, housings)
- Household Products (appliances, vacuum cleaner parts, power tools)
Description
Polyamide (PA), commonly known as Nylon, is a high-performance thermoplastic renowned for its strength, durability, and wear resistance. PA is available in various grades, such as PA6, PA66, and PA12, each offering different properties suited to specific applications. Nylon is used in injection molding for producing parts that need high tensile strength, abrasion resistance, and low friction. PA’s versatility makes it ideal for automotive, industrial, and consumer products, and it can be modified with additives for improved properties like UV resistance or flame retardancy.
Properties
- Mechanical Strength: PA offers excellent tensile strength and impact resistance, making it ideal for parts subjected to mechanical stress, such as gears, bearings, and automotive components.
- Wear and Abrasion Resistance: Exceptional resistance to wear and friction, making it perfect for moving parts or components in contact with other surfaces, like conveyor belts and wear strips.
- Chemical Resistance: Good resistance to oils, fuels, solvents, and various chemicals, which makes it suitable for use in automotive, industrial, and electrical applications.
- Moisture Absorption: PA is known to absorb moisture, which can affect its dimensional stability and mechanical properties. However, moisture-resistant grades are available for specific applications.
Common Applications
- Automotive Parts (gears, bearings, fuel lines, and interior components)
- Consumer Goods (zippers, textiles, and industrial products)
- Industrial Equipment (pulleys, bushings, conveyor belts)
- Electrical (connectors, electrical insulation)
- Medical Devices (surgical instruments, diagnostic equipment, and housings)
Description
Polybutylene Terephthalate (PBT) is a thermoplastic polyester that is known for its high strength, rigidity, and excellent dimensional stability. PBT is often used in injection molding due to its good processability and ability to withstand high temperatures and chemical environments. It offers good electrical insulating properties and is commonly used in automotive, electrical, and consumer goods applications. PBT is available in both unreinforced and reinforced (with glass fibers) grades, which enhance its mechanical properties for more demanding applications.
Properties
- Mechanical Strength: PBT has excellent tensile strength and rigidity, making it ideal for parts that require high structural integrity and dimensional stability, even under mechanical stress.
- Thermal Stability: Good resistance to heat and temperature extremes, with a high melting point, which allows it to maintain its shape and performance in high-temperature environments (up to 150°C/302°F).
- Chemical Resistance: PBT offers good resistance to oils, fuels, and solvents, as well as excellent moisture resistance, which makes it suitable for applications exposed to harsh environments.
- Electrical Insulation: PBT is widely used in electrical applications due to its good insulating properties and resistance to tracking and arcing.
Common Applications
- Automotive Parts (connectors, electrical housings, under-the-hood components)
- Electrical Components (connectors, switches, relays)
- Consumer Electronics (plugs, power supply housings)
- Industrial Equipment (gear components, bushings, and seals)
- Medical Devices (connector housings, diagnostic equipment)
Description
Polyoxymethylene (POM), commonly known by the brand name Delrin, is a high-performance thermoplastic known for its exceptional stiffness, low friction, and high wear resistance. POM is one of the most commonly used materials in injection molding for producing precision parts that require dimensional stability and high mechanical strength. It is available in both unreinforced and reinforced grades (often with glass fiber) to enhance its properties. Delrin is particularly known for its low moisture absorption and high chemical resistance, making it ideal for use in automotive, industrial, and consumer product applications.
Properties
- Mechanical Strength: POM offers excellent tensile strength and rigidity, maintaining dimensional stability even under heavy mechanical loads.
- Low Friction & Wear Resistance: Delrin has excellent sliding properties and is self-lubricating, making it ideal for moving parts like gears, bearings, and bushings that require minimal friction.
- Chemical Resistance: Outstanding resistance to a wide range of chemicals, including oils, fuels, and solvents, making it suitable for applications in harsh environments.
- Dimensional Stability: Low moisture absorption helps maintain dimensional stability over time, even in fluctuating humidity, ensuring consistent part performance in precision applications.
Common Applications
- Automotive Parts (gears, fuel system components, bearings, and bushings)
- Consumer Electronics (sliding components, gears, and precision connectors)
- Industrial Equipment (valves, pump components, and moving parts)
- Medical Devices (surgical instruments, diagnostic tools, and housings)
- Electrical Components (connectors, terminals, and switches
Description
Polyethylene Terephthalate (PET) is a versatile thermoplastic polyester widely used in injection molding due to its strength, clarity, and thermal stability. PET is commonly used in both unreinforced and reinforced forms (e.g., glass fiber-reinforced PET), offering improved mechanical properties for more demanding applications. It is well-known for its excellent chemical resistance, low moisture absorption, and good impact resistance, making it suitable for a wide range of applications in the automotive, consumer goods, and electrical industries. PET can also be recycled, making it an environmentally friendly option for many uses.
Properties
- Mechanical Strength: PET exhibits high tensile strength and rigidity, providing good structural integrity even under high-stress conditions.
- Thermal Stability: Excellent heat resistance, with a high melting point, allowing it to perform well in applications exposed to elevated temperatures (up to 250°C/482°F for reinforced grades).
- Chemical Resistance: Strong resistance to a variety of chemicals, including acids, alkalies, solvents, and oils, making it suitable for use in automotive, electrical, and industrial applications.
- Clarity & Surface Finish: PET has good optical clarity, making it ideal for products that require transparent parts or a smooth, glossy finish, such as bottles, containers, and light covers.
Common Applications
- Automotive Parts (bushings, connectors, and engine components)
- Consumer Goods (food containers, packaging, and household appliances)
- Electronics (connectors, switches, and housings)
- Industrial Equipment (gears, valves, and pump components)
- Medical Devices (packaging for medical devices, diagnostic equipment housings)
High-Performance Plastics
Description
Polyphenylene Sulfide (PPS) is a high-performance thermoplastic known for its excellent chemical resistance, high thermal stability, and outstanding dimensional stability. PPS is commonly used in injection molding for parts that need to withstand extreme temperatures and harsh chemical environments. It has a low moisture absorption rate and can maintain its mechanical properties at temperatures up to 260°C/500°F. PPS is often used in applications where both strength and resistance to aggressive substances are required, making it ideal for automotive, electrical, and industrial applications.
Properties
- Thermal Stability: PPS can operate at high temperatures (up to 260°C/500°F) without significant degradation of its mechanical properties, making it suitable for high-heat environments.
- Chemical Resistance: PPS has exceptional resistance to a wide variety of chemicals, including acids, bases, solvents, and fuels, making it ideal for corrosive environments.
- Dimensional Stability: Excellent dimensional stability even at elevated temperatures, which ensures that parts made from PPS maintain their shape and function over time, even under mechanical stress.
- Electrical Insulation: PPS offers excellent electrical insulating properties, which makes it useful for electrical components and insulation parts.
Common Applications
- Automotive Parts (fuel system components, engine parts, and under-the-hood applications)
- Electrical Components (connectors, switches, insulators, and housings for electrical systems)
- Industrial Equipment (seals, bearings, pumps, and valves)
- Chemical Processing (piping, gaskets, and fittings)
- Aerospace (lightweight, high-performance parts for aircraft components)
Description
Polyether Ether Ketone (PEEK) is a high-performance thermoplastic known for its exceptional mechanical properties, thermal stability, and chemical resistance. PEEK can withstand extreme temperatures (up to 250°C/482°F) and maintain its strength and dimensional stability. It is used in demanding applications where traditional materials might fail due to its excellent wear resistance, low friction, and outstanding chemical resistance to oils, fuels, and harsh chemicals. PEEK is commonly used in injection molding to produce high-performance components in industries such as aerospace, automotive, medical, and electrical.
Properties
- Thermal Stability: PEEK offers excellent heat resistance, capable of withstanding continuous service temperatures up to 250°C/482°F without degradation.
- Mechanical Strength: Outstanding tensile strength, rigidity, and impact resistance, making PEEK ideal for high-stress applications and parts that require dimensional stability.
- Chemical Resistance: Exceptional resistance to a wide variety of chemicals, including acids, alkalies, oils, fuels, and solvents, ensuring PEEK performs well in harsh environments.
- Wear Resistance & Low Friction: PEEK has superior wear resistance and low friction properties, making it ideal for moving parts like bearings, gears, and seals.
Common Applications
- Aerospace (components such as engine parts, valves, and seals)
- Automotive (high-performance components like fuel system parts, brake pads, and under-the-hood components)
- Medical Devices (implants, surgical instruments, diagnostic equipment)
- Electrical (connectors, insulating components, and circuit boards)
- Industrial Equipment (pumps, bearings, valves, and seals for high-temperature applications)
Description
Polyether Ketone (PEK) is a high-performance thermoplastic known for its superior mechanical strength, thermal stability, and chemical resistance. As a polymer with a structure similar to PEEK, but with a slightly lower molecular weight, PEK offers many of the same high-performance attributes while being more cost-effective. PEK is ideal for injection molding applications that require parts to maintain structural integrity in extreme temperatures and aggressive chemical environments. Its properties make it suitable for aerospace, automotive, and industrial applications where durability and reliability are essential.
Properties
- Thermal Stability: PEK exhibits excellent heat resistance, with a continuous service temperature up to 250°C/482°F, allowing it to perform well in high-temperature applications.
- Mechanical Strength: PEK is characterized by its high tensile strength, rigidity, and impact resistance, making it ideal for parts that require both strength and dimensional stability.
- Chemical Resistance: PEK shows exceptional resistance to a wide range of chemicals, including acids, alkalies, solvents, and oils, making it suitable for aggressive environments.
- Wear Resistance: With its high wear resistance and low friction coefficient, PEK is well-suited for use in moving parts such as bearings, gears, and seals.
Common Applications
- Aerospace (high-temperature components like engine parts, seals, and gaskets)
- Automotive (under-the-hood parts such as fuel components, brake systems, and transmission parts)
- Industrial Equipment (seals, valves, and components exposed to high wear and high-temperature conditions)
- Electrical (insulating materials, connectors, and circuit boards in extreme environments)
Thermoplastic Elastomers (TPEs)
Description
Thermoplastic Polyurethane (TPU) is a high-performance elastomer that combines the benefits of both rubber and plastics. Known for its flexibility, abrasion resistance, and elasticity, TPU is a thermoplastic that can be easily injection molded to produce parts with superior mechanical properties. It is available in a wide range of hardness levels, from soft and flexible to rigid, depending on the application. TPU is commonly used in industries such as automotive, medical, consumer goods, and sports equipment due to its high impact resistance, chemical resistance, and excellent wear properties.
Properties
- Flexibility & Elasticity: TPU offers high elasticity and flexibility, allowing it to return to its original shape after stretching or deformation, making it suitable for soft-touch parts like gaskets, seals, and flexible hoses.
- Abrasion Resistance: Known for its high wear resistance, TPU is used in parts that are exposed to abrasion or friction, such as wheels, belts, and protective coatings.
- Chemical Resistance: TPU has strong resistance to a wide range of chemicals, including oils, grease, and solvents, making it ideal for applications in automotive and industrial sectors.
- Thermal Stability: TPU has good heat resistance and can be used in a wide range of temperatures, typically from -40°C to 120°C (depending on the grade), maintaining its performance without significant degradation.
Common Applications
- Automotive Parts (gaskets, seals, hoses, and impact-resistant bumpers)
- Medical Devices (catheters, tubing, and medical seals)
- Consumer Goods (phone cases, footwear, and sporting equipment)
- Industrial Equipment (conveyor belts, protective coatings, and damping elements)
- Electronics (cable sheathing, connectors, and flexible housings)
Description
Thermoplastic Vulcanizate (TPV) is a high-performance elastomeric material that combines the properties of thermoplastic and vulcanized rubber. TPV is produced through a process where rubber is crosslinked (vulcanized) within a thermoplastic matrix, allowing it to offer rubber-like properties with the processability of a thermoplastic. TPV can be easily injection molded into soft, flexible parts while maintaining excellent dimensional stability and chemical resistance. It is commonly used in automotive, industrial, and consumer product applications where flexibility, durability, and environmental resistance are critical.
Properties
- Elasticity & Flexibility: TPV exhibits excellent flexibility and elasticity, similar to rubber, while still offering the ability to be molded like thermoplastics. This makes it ideal for applications that require flexible seals, gaskets, and rubber-like parts.
- Chemical Resistance: TPV shows strong resistance to a wide variety of chemicals, including oils, greases, solvents, and fuel, making it suitable for harsh industrial and automotive environments.
- Thermal Stability: TPV can perform in a wide temperature range, typically from -40°C to 120°C, with minimal degradation, making it suitable for both low and high-temperature applications.
- Wear & Abrasion Resistance: TPV is known for its abrasion resistance and long-lasting durability, particularly in applications where parts are subject to frequent contact or friction, such as seals, gaskets, and protective covers.
Common Applications
- Automotive Parts (seals, gaskets, weather stripping, and vibration dampeners)
- Industrial Equipment (rubber-like components for machinery, seals, and wear-resistant parts)
- Consumer Goods (footwear, flexible tubing, and durable elastomeric parts)
- Electronics (protective covers, cable sheathing, and seals)
- Medical Devices (soft-touch parts, seals, and gaskets for medical devices)
Transparent & Optical Plastics
Description
Polymethyl Methacrylate (PMMA), also known as acrylic, is a transparent thermoplastic known for its excellent optical clarity, weather resistance, and UV stability. PMMA is often used as a shatterproof alternative to glass due to its high impact resistance and ability to be molded into a wide variety of shapes and sizes. In injection molding, PMMA is valued for its ability to produce crystal-clear parts with smooth surfaces, making it ideal for applications requiring visibility or aesthetic appeal. It is commonly used in automotive, electronics, signage, and consumer product industries.
Properties
- Optical Clarity: PMMA is highly transparent and has excellent light transmission properties (up to 92%), making it an ideal choice for parts that require optical clarity, such as lenses, light covers, and displays.
- Impact Resistance: Although not as tough as polycarbonate, PMMA is highly impact-resistant compared to glass, making it a suitable alternative in applications requiring shatter resistance.
- UV Resistance: PMMA has excellent UV resistance, which helps it maintain its transparency and surface quality when exposed to sunlight or harsh environmental conditions.
- Weather Resistance: PMMA is highly resistant to weathering, making it durable for both indoor and outdoor applications, even when exposed to extreme temperatures or moisture.
Common Applications
- Automotive (headlight lenses, light covers, and window panels)
- Signage & Displays (store signs, point-of-purchase displays, and acrylic sheets)
- Consumer Goods (cosmetic containers, household products, and protective covers)
- Electronics (light diffusers, LED housings, and electronic device screens)
- Lighting (light fixtures, lens covers, and lighting panels)
Ultra-High Molecular Weight Plastics
UPE (Ultra-High-Molecular-Weight Polyethylene)
Description
Ultra-High-Molecular-Weight Polyethylene (UPE) is a high-performance thermoplastic known for its exceptional strength, wear resistance, and low friction properties. UPE is a variant of polyethylene with a molecular weight that is significantly higher than standard HDPE (High-Density Polyethylene), giving it enhanced mechanical properties. It is typically used for applications that require high durability and resistance to abrasion and impact. UPE is often processed through injection molding to create components that must withstand extreme conditions such as heavy wear and high-stress environments.
Properties
- Wear Resistance: UPE exhibits outstanding wear resistance, making it ideal for parts exposed to friction and abrasive conditions, such as sliding components and bearings.
- High Strength & Toughness: UPE has extremely high tensile strength and impact resistance, even at low temperatures, making it suitable for high-load applications.
- Low Friction: UPE has a low coefficient of friction, enabling it to be used in moving parts where reduced friction is important, such as gears, pulleys, and seals.
- Chemical Resistance: UPE is highly resistant to most chemicals, including acids, alkalies, and organic solvents, making it ideal for use in harsh industrial environments.
Common Applications
- Industrial Equipment (bearings, bushings, and wear plates)
- Conveyor Systems (sliding components, rollers, and chutes)
- Mining (liners and wear-resistant components)
- Food Processing (chutes, liners, and conveyor belts)
- Medical Devices (artificial joints and implants)
Description
Very High Molecular Weight High-Density Polyethylene (VHMWHDPE) is a specialized form of HDPE that possesses a higher molecular weight, leading to enhanced mechanical properties. This material offers a combination of high-density polyethylene’s strength and chemical resistance, with the added benefits of superior abrasion resistance and impact strength. VHMWHDPE is widely used for demanding applications requiring long-lasting, durable components in industries like automotive, industrial, and food processing. It is often chosen for parts that need to withstand harsh operating conditions while being easy to process using injection molding.
Properties
- Superior Wear Resistance: VHMWHDPE offers exceptional wear resistance, making it ideal for parts subjected to heavy friction, such as sliding components, conveyor belts, and wear plates.
- High Impact Strength: It has outstanding toughness and resistance to impact, even in low temperatures, which makes it suitable for high-stress applications where parts may experience shocks or heavy loads.
- Chemical Resistance: VHMWHDPE is highly resistant to acids, alkalies, and organic solvents, allowing it to be used in corrosive environments without degradation.
- Low Friction: With a low coefficient of friction, VHMWHDPE is often used in sliding and bearing components to reduce wear and improve efficiency.
Common Applications
- Industrial Equipment (bearings, bushings, and wear plates)
- Conveyor Systems (conveyor belts, rollers, and chutes)
- Food Processing (food conveyor liners, hoppers, and processing components)
- Automotive (impact-resistant parts and liners)
- Marine (mooring pads, wear-resistant liners, and dock bumpers)
Specialty Engineering Plastics
Description
Polyphenylene Oxide (PPO) is a high-performance thermoplastic polymer known for its exceptional thermal stability, dimensional stability, and electrical insulating properties. PPO is widely used in applications where both high strength and resilience are required, particularly in automotive, electronics, and industrial components. Due to its low moisture absorption and excellent chemical resistance, PPO can be processed through injection molding to create precise, durable parts for a wide range of industries. It is often blended with other materials, such as polystyrene or polyamide, to further improve specific properties.
Properties
- Thermal Stability: PPO offers excellent heat resistance, maintaining its mechanical properties even at elevated temperatures, typically up to 200°C, making it suitable for high-temperature applications.
- Dimensional Stability: PPO exhibits low thermal expansion and minimal moisture absorption, ensuring that molded parts maintain their shape and size in demanding environments.
- Electrical Insulation: Known for its excellent electrical insulating properties, PPO is commonly used in electrical and electronic components that require protection from electrical current.
- Chemical Resistance: PPO is highly resistant to organic solvents, alkalies, and acids, making it suitable for use in harsh chemical environments.
Common Applications
- Automotive (electrical connectors, fuel system components, and engine parts)
- Electronics (circuit boards, connectors, and switchgear)
- Industrial Equipment (pump housings, valves, and fluid handling systems)
- Home Appliances (appliance components, housings, and casings)
- Medical Devices (insulating parts for diagnostic equipment)
High-Density and High-Performance Polyethylenes
Description
High-Density Polyethylene (HDPE) is a stiff, durable thermoplastic with a high strength-to-density ratio. It is known for its excellent chemical resistance, impact strength, and low moisture absorption. HDPE is widely used in injection molding to produce robust parts that are both cost-effective and versatile. Its relatively low processing temperatures make it easy to mold, and it can be used for a wide range of applications, from consumer goods to industrial components. HDPE’s ability to withstand environmental stress and chemicals makes it an ideal choice for outdoor and heavy-duty applications.
Properties
- Chemical Resistance: HDPE exhibits exceptional resistance to acids, alkalies, alcohols, and solvents, making it ideal for chemical processing environments and outdoor products.
- Impact Strength: It is known for its high impact resistance, even in low temperatures, which ensures that parts made from HDPE remain durable and functional under stress.
- Moisture Resistance: HDPE has low moisture absorption, making it suitable for use in wet or submerged environments without degrading.
- UV Resistance: HDPE can be enhanced with UV stabilizers to improve its weatherability, making it ideal for outdoor applications exposed to sunlight.
Common Applications
- Consumer Goods (bottles, containers, and toys)
- Packaging (bottles, caps, and food containers)
- Industrial Equipment (pipes, fittings, and tanks)
- Outdoor Products (plastic lumber, storage bins, and agricultural films)
- Automotive (fuel tanks, bumpers, and panels)
Customized Material Solutions
Additionally, we also offer the ability to develop customized plastic materials tailored to meet your specific performance requirements. Whether your project demands enhanced electric conduction, heat conduction, electromagnetic shielding, or the ability to withstand high temperatures or high-strength conditions.
We can incorporate specialized additives and reinforcements to achieve the desired properties. These may include advanced materials such as carbon fiber, graphene, glass fiber, steel fibers, and more, to deliver materials with exceptional performance in challenging environments.
Success Story: Delivering Cost Efficiency and Scalability for Solar Bearing Bushings
1. Optimizing Costs with High-Quality Materials
In 2017, XDL Machinery started working with our valued customer from the UK on the supply of high-quality plastic bearing bushings for solar tracking systems. Initially, the customer selected a premium material, but we conducted a detailed analysis to optimize both cost and quality.
- Identified a more cost-effective alternative material that met all performance requirements.
- New material doubled durability while reducing costs by two-thirds.
- Developed testing equipment and conducted cycle simulation tests to validate the new material’s performance.
- The customer adopted the new material, making it their preferred choice for these applications.
2. Seamless PPAP Process and Full Compliance
We successfully worked with the customer through the Production Part Approval Process (PPAP), ensuring all documentation and compliance standards were met, providing peace of mind for both parties.
3. Scaling Production to Meet Growing Demand
As the customer’s business rapidly expanded, demand surged from 60,000 pieces per month to 300,000 within 30 days. XDL Machinery and its partners responded swiftly by:
- Investing in 10 additional injection molding machines.
- Manufacturing 10 extra molds to increase production capacity.
- Hiring 20+ additional skilled workers to meet the increased output.
- Successfully scaling production in just 30 days to fulfill the customer’s growing needs.
4. Achieving Zero Defects and High Customer Satisfaction
Since the beginning of our partnership, XDL Machinery has delivered over 6 million bushings with zero defects and no non-conformance issues.
- The customer expressed high satisfaction with our quality and efficiency.
- Our commitment to delivering cost-effective, scalable, and high-quality solutions has strengthened our relationship and earned the customer’s trust.
We are fully confident in our ability to continue delivering high-quality, cost-effective, and scalable solutions for our valued customer. We always are ready to meet the evolving needs of our customers and ensure long-term success in every project.
Industries We Serve
- Our plastic injection molding services support a broad range of industries, providing high-performance components tailored to meet the specific needs and applications of each sector:
- Solar Photovoltaic Industry
- Industrial Electronics
- Industrial Equipment
- Consumer Electronics
- Automotive Industry
- Packaging Industry
- Building and Window Systems
- Enviornmental Engery Storage
FAQs: Your Queries Answered
A: We specialize in the following injection molding processes：
- Special composite materials,
- High-temperature injection molding,
- Thermally and electrically conductive materials injection molding,
- Insert molding.
A: Yes, we can assist customers by selecting materials, product shapes, thicknesses, and other design aspects based on their needs to enhance their market competitiveness.
A: Yes, we offer free mold flow analysis and Design for Manufacturing (DFM) services before mold production.
A: Absolutely. Please see the following measures:
- Material Selection: We choose raw materials that match the physical properties of the product, such as melt flow index, ensuring uniform distribution and stable performance, which effectively reduces dimensional deviation.
- Precision Mold Design:
- We use precise mold design to minimize dimensional deviations and enhance the accuracy of injection-molded parts.
- Advanced mold manufacturing techniques are employed to improve the precision and stability of the molds.
- Our molds feature well-designed gating systems for efficient mold filling and uniform cooling systems to ensure the precision and stability of injection-molded parts.
- Control of Material Conditions: We strictly control the humidity and temperature of raw materials, ensuring they are used under optimal conditions to reduce the impact of process conditions on dimensional accuracy.
- Rigorous Product Control: We have comprehensive and strict product control processes, ensuring representative identification of product characteristics.
- Trial Molding: Trial molding is crucial. Stable process conditions must be achieved before mass production can commence.
- Regular Mold Maintenance: We conduct regular inspections and maintenance of molds to prevent wear from affecting dimensional accuracy. Timely maintenance and care are essential to ensure stability.
A: Our tolerances can be as precise as ±0.05mm, depending primarily on the size of the product and the shrinkage rate of the material used.
A: We can handle mold design, manufacturing, and maintenance. Our typical timelines are as follows:
- Standard molds: 20-30 days
- Complex molds: 30-45 days
- Large, complex molds:45- 60 days
A: Our molds are typically made of materials such as NAK80, SKD61, and S136.
A: From product and mold design to incoming raw material inspection, and throughout the production process inspection and monitoring, we strictly adhere to IATF16949 system standards. Utilizing precision testing equipment and professional inspection techniques, we strive to achieve zero defects in our products.
A: We ensure the accuracy of critical dimensions through a thorough inspection process:
- Initial inspection at the start of production.
- Engineering patrol inspections every 3 hours.
- 5% sampling inspection before shipment.
- 100% inspection of critical fit dimensions.
A: At the start of production, the first five pieces are discarded. Beginning with the sixth piece, we conduct first article inspection(FAI), typically checking three molds. If the dimensions are within specifications, we proceed with mass production. Inspections are conducted after the parts have completely cooled.
