Custom Molding Services

About Us

Shanghai Starway Engineering & Manufacturing Co., Ltd. specialized in top-notch custom CNC machining services, Since 2011.The company covers an area of 7,000 square meters, the annual sales of 80 million yuan, about 150 employees, has passed the iso9001:2015 quality management system certification. Starway has 8 engineers, 10 project coordinators, and 120 skilled employees. Our own factory and professional staff enable us to complete rapid prototyping and mass production in 1-2 weeks.We specialize in providing one-stop Custom Molding Services , from material selection to mold manufacturing, from surface treatment to packaging and delivery, we can do not need you to spend time and cost to find the corresponding supplier, we help you to carry out the full link integration processing, making the product from concept to molding processing cycle shorter, more energy saving, more convenient after-sales, more simple cooperation

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What is Custom Molding Services?

Custom molding service is a general term for plastic manufacturing process services, including some processes Injection molding，Overmolding，Insert molding，Gas-assisted injection molding，Two-shot molding，Co-injection molding

In the early stage of determining the use of injection molding, we will first design the mold through CAD and other ways to create a mold that meets the processing requirements. The complexity and quality of a mold design can directly determine the accuracy and quality of subsequent product molding. As a result, significant resources are often required at this stage.

This process is often used when making plastic parts on a large scale because of its low material waste and low cost per part. Compared to other materials, plastics are cheaper and more efficient to process.

Our Custom Molding Services process produces custom prototypes and end-use production parts with delivery times of up to 3-5 day. When determining the mold is correct, we can reach 24 hours of uninterrupted production of molded products, which can greatly reduce the processing cycle, and we also store more than 200 kinds of processing materials to meet the different requirements of the processing process

Custom Molding Services Capabilities

Our basic guidelines for Custom Molding Services include important mold design to help improve the accuracy of the finished product, the appearance of cleanliness, and reduce the overall production time.

Service	Single
Preparation Time	Including quotation time with Design Manufacturing (DFM) feedback approximately 3-5 days
Production Planning	Consult with your internal meeting to discuss the specific production process
Materials	Most plastics, including custom sourcing and matching
Machines Available	Single, multi-cavity, and family molds; 50 to 1,100+ press tonnage
Mold Ownership	The product is owned by the customer
Mold Cavity Tolerances	+/- 0.005" when machining the mold and an additional +/- 0.002" per inch when calculating for shrink rate
Part to Part Repeatability	+/- 0.004" or less
Specified position tolerance	ighter tolerances can be requested and may increase the cost of tooling because of additional sampling and grooming.
Mold production material	Steel and aluminum; Production grades range from Class 105, a prototype mold, to Class 101, an extremely high production mold.
Mould Life	300000-500000 Shots
Mold Standard	LKM, HASCO, DME or upon customer's requirement

This table describes the general tolerances, radii and types of molds that can be manufactured for Starway custom molding services. Contact us to learn more about injection molding standards.

What Can We Offer You

Depending on your application requirements, when you request a customized molding service quote or product processing, you can ask us to provide the following reports or inspection certificates:

Designing for Manufacturability Feedback (DFM)
Scientific molding process development report
In-process CMM inspection and machine monitoring
First article inspection (FAI) and process capability report with GD&T
Product SOP report during production

How Does Plastic Injection Molding Work?

The manufacturing process of parts in injection molding is complex. Before your product takes shape, we provide you with a team of professional engineers to discuss manufacturability feedback and design consulting services through online meetings with you, so you can avoid mold design pitfalls before the material enters the mold. Through the communication of the team to determine the feasibility of the product Our engineering team will make every effort to create a mold that conforms to the high precision molding of the product. From there, you can get the consistency of high quality products as well as the high efficiency of product production.

Your critical mass (CTQ) size requirements for your model let us know which details are critical to the success of your part. Once the mold is completed separately, after the first product molding is completed, our professional inspection team will analyze all aspects of the product, including the hardness of the material, whether the accuracy of the product meets the production requirements, we will send the first batch of products and inspection certificates to you, when the production is licensed, we will produce this batch of parts with the fastest efficiency.

The operation of the injection molding machine usually starts with the thermoplastic particles being put into the injection hopper and the thermoplastic particles are heated to melt in the heating barrel of the injection machine during the heating process. The spiral rod rotates to help the thermoplastic particles to fuse evenly forward. With the advance of the screw, the melted thermoplastic particles will be injected into the mold cavity (the interior of the mold cavity is under high pressure) when injected into the mold cavity. The cooling water circulation in the cooling system will quickly cool the plastic in the mold cavity. After the cooling is completed, the mold can be opened and the plastic parts will be pushed out of the mold. If you need follow-up processing, you can choose whether to remove the flash or whether you need to polish, spray and other processes.

Our Custom Molding Services Technology

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Injection molding

The most widely used method, where molten plastic is injected into a mold cavity under high pressure and cooled to form the desired shape.

Overmolding

Involves molding one material over another, typically to provide additional features or improve grip.

Insert molding

Involves placing metal or plastic inserts into the mold cavity before injection, allowing for the creation of parts with integrated components.

Gas-assisted injection molding

Uses nitrogen gas to assist in the injection process, reducing material use and improving part strength.

Two-shot molding

Involves injecting two different materials into the mold in separate stages, allowing for the creation of parts with multiple colors or materials.

Co-injection molding

Similar to two-shot molding, but involves injecting two different materials simultaneously into the mold, allowing for the creation of parts with a core and outer layer.

We Commonly Use Plastic Materials

PP

Polypropylene is a common thermoplastic with good chemical resistance and mechanical properties. It is widely used in the manufacturing of various plastic products such as bottle caps, containers, pipes, and automotive parts.

PE

Polyethylene is a common plastic and comes in different types such as high-density polyethylene (HDPE) and low-density polyethylene (LDPE). It is used for making plastic bags, bottles, plastic films, and garbage bags, among other things.

PVC

PVC is a common plastic known for its chemical resistance and weather resistance. It is used in the production of water pipes, cable insulation, window frames, flooring, and more.

PS

Polystyrene is a common plastic with two main types: General Purpose Polystyrene (GPPS) and High Impact Polystyrene (HIPS). It is used in making foam cups, food containers, electronic packaging, etc.

PET

PET is a transparent and durable plastic commonly used for manufacturing plastic bottles, food packaging, fibers, and textiles.

PC

Polycarbonate is a high-strength and heat-resistant plastic often used in the production of safety glasses, phone screens, CDs, and automotive parts.

PMMA

PMMA is a transparent plastic used for making transparent sheets, decorations, automotive lamp covers, and eyeglass lenses.

ABS

ABS plastic is known for its impact resistance and mechanical properties, and it is used for making appliance housings, toys, and automotive parts.

PLA

PLA is a biodegradable bio-plastic widely used in disposable tableware, packaging materials, and medical implants.

Our Surface Finishing

Painting

Applying paint coatings to enhance color, gloss, or surface protection

Coating

Applying special coatings to improve wear resistance, corrosion resistance, or other specific properties.

Atmospheric plasma treatment

Improving surface adhesion, cleanliness, and wetting properties by placing injection molded products in special atmospheres, such as hydrogen, oxygen, etc.

Printing

Adding patterns, text, or logos onto the surface of injection molded products for decoration or branding purposes.

Polishing

Mechanical polishing of the surface to improve smoothness and appearance quality.

Hot stamping

Using hot stamping or foil stamping techniques on the surface of injection molded products to enhance decoration or brand awareness.

Mold Knowledge for Custom Molding Services

The following table for mold development and production of some processing parameters can be used as reference conditions. In the custom prototype service, the mold is the key to the whole service. Our prototyping process can help you reduce product development cycles by weeks, sometimes months, and produce molded parts in a matter of days. Our on-demand manufacturing processes are designed to meet your production needs, enabling a seamless transition into production to ensure your parts display and perform as expected

Type	Prototyping	On-Demand Manufacturing
Objective	Complete individual mold development according to customer requirements according to CAD	Arrange reasonable processing cycle according to customer's production quantity
Best When	Key focus is to reduce design risk, increase R&D	Design is finalized and run-to-run part consistency is critical
	productivity, and iterate faster to reduce time to market	Key focus is to improve quality, reduce cost, and mitigate supply chain risk
	Typical Quantities <2,000	Process development, qualification documentation, and mold capability information is required
Mold Cavities	Single	Single and multi-cavity
Mold Life	Limited (guaranteed for at least 2,000 shots)	Unlimited
Mold Storage	Stored for 18 months of inactivity	Stored for 3 years of inactivity
Mold Ownership	You	Yes
Shared Features	Aluminum molds Standard lead times as fast as 7 days Tolerances of +/-0.003 in. plus resin tolerance (in./in.) Set-up fees apply to each run Consultative Design Services (CDS) Finishing Options No minimum order quantities (MOQ) Quick-turn shipping in as fast as 1 day

FAQ

Q: What is the cost of creating a mold separately？

A: Generally speaking, the cost of creating a mold is usually higher, because the quality of the mold will directly affect the quality of the product during production, for small batches of customized orders is not necessary to create a mold, but for mass production, after a separate mold, the cost of each single piece will be reduced, which is economic in the long run

Q: Can you customize the mold？

A: Yes, we can create a unique mold for product production according to the details and processing characteristics provided by you in accordance with CAD methods. When the mold is successfully built, the cost price of the production of the product will be greatly reduced, and it is the cheapest in the long run. If the mold is damaged, it can be rebuilt at the first time

Q: What is the tolerance of your mold after completion？

A: In most cases, the tooling we create can maintain a machining tolerance of +/ -0.003 in. (0.08mm), including material tolerance may be greater than but not less than +/- 0.002 in /in. The tolerance parameters of the detailed parts can also be handled separately according to the material requirements

Q: Who the mold belongs to

A: The ownership of all molds manufactured by us is yours. After the completion of conventional processing and molding, you can choose whether to take the molds away together according to your requirements, but the costs incurred during transportation will be borne by you. If you are not sure about the applicability of the molds, our engineers will discuss with you

Q: Can you make the same material can reflect different colors？

A: Yes, of course you can do color matching in the same material! You only need to tell us the specific details of the product during processing and the parts that need to be processed during production. However, when multiple colors are run on the same order, the cleanup fee will be increased.

How to cooperate with us

Here are some of the most common ways Starway works with you

Provide customized parts information

First confirm the detailed requirements of the product, including design drawings, material specifications, processing accuracy requirements, etc. At this stage, you need to ensure that both parties have the same understanding of the product requirements.

Quotation and budget negotiation

According to the design documents and requirements provided by customers, make cost estimation and quotation, and both parties determine the production time under the agreement of budget and cost (provide quotation service 24 hours a day).

Production planning and production process monitoring

Make production plan according to product characteristics, including processing technology, machine equipment selection, human resources arrangement, etc,And in the production process, we will strictly monitor the steps of product processing every week and generate weekly reports to customers to ensure that customers understand the progress of products

Sample confirmation and production

Once the production time is determined, we will first make a sample or prototype of the product and submit it to the customer for confirmation. The customer checks and tests the samples to ensure that they meet the design requirements and quality standards, and then approves the formal production. (Our proofing time is 3-7 days)

Product inspection and testing

After the completion of production, we will conduct a comprehensive inspection and testing of the product, including dimensional measurement, functional testing, etc., to ensure that the quality and performance of the product meet the standards. We will then pack the product to prevent damage during transportation

We're well-known as one of the leading custom molding services manufacturers and suppliers in China. If you are going to wholesale customized custom molding services at competitive price, welcome to get more information from our factory.

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