Injection Molding Services

From prototypes to production, KaiSpeed delivers precision tooling and molded parts with free DFM, fast T1 samples, and one-stop finishing and light assembly.

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Injection Molding Services

Injection Mold Tooling

Get custom aluminum or soft-steel (P20/NAK80) molds tailored to your part and resin. We design for manufacturability, optimize gates/vents/ejectors, and deliver fast T1 samples with production-grade cosmetics.
Typical capability: cavity features to ~±0.05 mm (feature-dependent); SPI A–D, VDI/Mold-Tech-style textures. Mold-flow/advanced DFM available on request.

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Insert Molding

Combine engineering plastics with pre-placed metal inserts (e.g., brass threaded inserts, studs, contacts) during molding to boost strength, wear, and serviceability—no extra fasteners required. Inserts can be hand-loaded or fixtured for repeatability; ultrasonic staking and post-ops also available when appropriate.

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Overmolding

Create durable, integrated parts by molding one material over a rigid substrate (plastic or metal). Ideal for soft-touch grips, seals, color accents, and impact protection. We support mechanical interlocks and chemical adhesion strategies, with Shore hardness selection tuned to your use case.
Good pairs: PC/ABS + TPE/TPU, Nylon (±GF) + TPE, Metal inserts + TPE overmold. Texture and color-match available

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Advantages of KaiSpeed’s Injection Molding Service

  • Extensive material options

    From ABS, PC/ABS, PC, PP/PE, PA (±GF), POM, PMMA, PETG to PEI/PEEK, PPS, PPA, LCP and TPU/TPE/TPV. Color-match (Pantone/RAL), FR/UV/ESD/medical grades, and documentation (e.g., RoHS/REACH) available.

  • Versatile equipment & tooling strategies

    Single or multi-cavity, bridge or production tools, with a broad press range (small to 1,000-ton class via our network). We tune gate/runner/ejector layouts for throughput, yield, and cosmetics.

  • Production-grade tooling, fast T1

    Aluminum and P20/NAK80 tools with engineer-led DFM. T1 as fast as ~2 weeks for simple open-shut tools (expedite case-by-case). We supply first-article packs and clear feedback for rapid approval. Mold-flow available on request.

  • Precision & quality you can audit

    Tight, production-realistic tolerances with controlled process windows. FAI/CMM, material certs, and PPAP/CPK/SPC on request. Cosmetic control for SPI/VDI/Mold-Tech-style surfaces.

  • Scalable from prototype to production

    No strict MOQ. Start with pilot runs and ramp confidently—family tools, hand-loads, side actions, insert- and overmolding supported. Flexible fulfillment (kanban / stock-&-release) keeps you on schedule.

Why KaiSpeed

  • Tooling + molding under one roof: Aluminum and soft-steel tools, rapid iterations, and stable runs.

  • Engineer-led DFM: Draft, wall uniformity, ribs/bosses, gate & ejector layout, knit-line/warp risk, texture allowances.

  • Production resins & finishes: Mold real thermoplastics with SPI/VDI/Mold-Tech-style surfaces, color match, and post-ops.

  • Clear quality path: FAI/CMM, material certs, and PPAP/CPK/SPC on request.

24/7 Support • Fast Global Delivery • Secure NDA Protection

How to Work With Us

01. Send Files & Requirements

Share STEP/IGES + PDF drawing with resin, color/finish, quantities, critical dimensions/cosmetic faces, and any standards/docs. (NDA welcome.)

02. DFM Review & Quote

We analyze draft/walls, ribs/bosses, gates/vents/parting, ejectors, texture allowances, and risk (sink/warp/knit). You’ll get a line-item quote, cost-down options, and a schedule to T1.

03. Tool Build & T1 Samples

CNC/EDM toolmaking → polish/texture → T1 shots with photos and inspection summary. We iterate to T2 (if needed) until approval.

04. Production & Delivery

Mold to spec, apply finishes/overmold/inserts/light assembly, and run QC (FAI/CMM; PPAP/CPK on request). We pack & ship with labeling and documentation per your requirements.

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Injection Molding Materials

Once your tool is approved, we mold functional prototypes and production parts in a wide range of thermoplastics and elastomers. If you need a specific grade (e.g., GF, UV-stabilized, FR UL94, medical/food-contact, ESD), we’ll source it or propose equivalents.

Rigid Thermoplastics (common)

  • ABS / ASA – General-purpose toughness; ASA adds UV/weather resistance for outdoor use.

  • PC / PC-ABS / PC-PBT / PC-PET – High impact; blends improve chemical and heat performance.

  • PA6 / PA66 (Nylon, ±GF) – Strong & wear-resistant; glass-filled grades for stiffness.

  • POM/Acetal (Copolymer & Homopolymer/Delrin®) – Low friction, great dimensional stability.

  • PP / PE (HDPE / LDPE / LLDPE / UHMW-PE) – Chemical resistance, ductility; food-grade options available.

  • PMMA (Acrylic) / PET / PETG – Clear/translucent optics; PMMA has best clarity & scratch resistance; PC is tougher.

  • PBT / PBT-blends – Electrical & automotive workhorse; good chemical/creep resistance.

  • SAN / PS – Clear (SAN) or general commodity (PS) for low-load parts.

  • TPO – Flexible polyolefin with good chemical resistance.

  • PEI (ULTEM™) – High heat & flame resistance; stable, medical/industrial.

  • PEEK – Exceptional strength/heat/chemical resistance; metal-replacement in demanding applications.

  • PPS / PPA / LCP – Thin-wall, high-temp, electronic connectors, precision parts.

  • PSU / PES – Rigid, transparent, chemically resistant engineering polymers.

  • TPU / TPE (Shore A → Shore D) – Soft-touch grips, seals, bellows; abrasion & impact resistant.

  • TPV (e.g., Santoprene®) – Good compression set & temperature resistance.

  • PEBA – Lightweight, resilient; medical/sports applications.

  • EPDM – Weather/ozone resistant; seals & gaskets.

  • FKM (Viton®) – Excellent fuel/oil/chemical resistance; high-temp.

  • PVC (Shore A) – Flexible, economical elastomer (plasticizer-modified).

  • LSR (Liquid Silicone Rubber) – Biocompatible, high-temp, excellent flexibility; requires dedicated silicone tooling/process (different from thermoplastic molding).

Mold & Part Finishes / Post-Processing

Mold Surface Standards

  • SPI A-1 ~ D-3 – From high-polish (diamond) to stone finishes.

  • VDI 3400 – EDM-based matte textures (fine → coarse).

  • Mold-Texture (Mold-Tech-style) – Patterns, grains, swirls (specify code or sample).

Part Finishing & Value-Adds

  • As-molded or bead-blast/brush, paint, dye (where applicable)

  • Laser marking / engraving, pad/silk printing, decals

  • Threaded insert installation (UN/metric), ultrasonic welding, solvent bonding

  • Light assembly and custom packaging/labeling to spec

  • Color: Pantone/RAL color-match; gloss/matte/satin

FAQs

Yes—when you need material-true parts and production-like cosmetics. For ≤10 pcs or very early iterations, CNC/3DP may be more economical; we’ll advise.

No strict MOQ. We support single prototype shots up through pilot and bridge runs.

Simple open-shut tools often reach T1 in ~2–3 weeks; after approval, hundreds of parts can ship quickly. Complexity and cosmetics affect timing.

Yes. We support overmold (soft-touch) and insert-molding (bosses, studs, brass inserts). We’ll confirm gate/fixture strategy during DFM.

Yes. We maintain and store customer molds and can run repeat orders for the duration of tool life. Ownership and custody are specified in your PO.

Standard DFM is included; mold-flow and parting/side-action studies are available on request for complex parts.

Mutual NDA, secure file handling, controlled vendor routing, and mold custody procedures. We share documentation as required.

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