Injection Molding

Injection Molding Services

Injection molding is a high-precision manufacturing process used to produce plastic parts by injecting molten thermoplastic material into a custom-designed mold cavity. Once cooled and solidified, the part is ejected in a finished or near-finished state, enabling high repeatability, tight tolerances, and efficient mass production.

Hi-Rel Plastics specializes in high-precision custom plastic injection molding, delivering reliable solutions for a wide range of industries. Since 1984, we have built a reputation for quality, consistency, and engineering excellence.

We offer complete injection molding services from concept to production, including part evaluation, design support, prototyping, mold design, tooling, sampling, and full-scale manufacturing. Our experienced engineering team focuses on design for manufacturability (DFM) to optimize performance, reduce costs, and ensure efficient production.

Our facility is equipped to process a broad range of engineering-grade thermoplastics such as PEEK, PEI (ULTEM), PPS, PPSU, PES, PBT, PVDF, LCP, Glass filled Nylon ( PA6, PA66, PA12), PC, PC/ABS, ABS, ACETAL, PP, HIPS, HDPE, LDPE, Thermoplastic elastomers (TPE, TPV, TPU), LSR, PMMA(acrylic or plexiglass), PVC, CPVC etc. and many other specialty materials. We manufacture complex components with tight tolerances up to ±0.001 inch, maintaining extremely low rejection rates and superior quality standards.

With 40+ years of experience, advanced molding technology, and ISO-certified systems (ISO 9001:2015, AS9100 Rev D, ISO 13485:2016), we are a trusted partner for highperformance and critical applications. Our ISO 7 (Class 10,000) cleanroom capability further supports sensitive and regulated industries.

Capabilities

Our Injection Molding services include:

Highly-Reliable, high-precision, high-quality injection molding for complex and tight-tolerance plastic components for a wide range of industries using advanced thermoplastic materials and engineered resins.
Cost-effective solutions tailored to customer specifications and demanding industry standards
Prototype, low-volume, and high-volume production molding capabilities
Material selection support
Single-shot and multi-shot molding for multi-material and multi-color parts
Over molding and insert molding integration for enhanced part functionality
Vertical injection molding for insert, over molding, multi-cavity molding, micro molding, clean room injection molding
Mold design support, tooling optimization, and DFM (Design for Manufacturability) assistance. Tool transfer, maintenance, and refurbishment support
Press sizes up to 900 tons with 3-axis servo robot capability
Automation and robotics (part & sprue picking & placing robots, custom fixtures, automation components, in-mold labeling and in-mold decorating processes) to enhance part quality and consistency; reduce molding labor and part costs; minimize part-to-part variation and waste; and increase machine utilization and efficiency.
Finishing & secondary operations such as trimming, inspection, assembly & packaging
On-time delivery with JIT (Kanban) programs

Key Materials for Injection Molding:

Polypropylene (PP): A lightweight, cost-effective, and chemically resistant material often used in packaging and consumer products.
Acrylonitrile Butadiene Styrene (ABS): Highly popular for electronics and consumer goods due to its stability, ease of molding, and good impact resistance.
Nylon (PA6, PA66): Often used with glass filling for high-strength, durable, and temperature-resistant applications, such as automotive under-hood components or electrical connectors.
Polycarbonate (PC): Used when high impact strength, transparency, and superior insulation properties are required.
Polyethylene (PE – HDPE/LDPE): Ideal for flexible, high-wear applications, such as caps, containers, and household items.
Polyether ether keton (PEEK): High-performance, high-temperature plastic suitable for specialized medical or aerospace components.
Polyetherimide (PEI): Excellent heat resistance, high strength, dimensional stability, and inherent flame resistance; commonly used in demanding electrical, automotive, aerospace, and medical applications.
Thermoplastic Polyurethane (TPU): Flexible, abrasion-resistant, offering excellent elasticity, impact strength, and chemical resistance.
Styrenic Block Copolymers (TPE-S / SBS): Flexible, rubber-like softness, good elasticity, and excellent processing ease.

Common Injection Molding Applications:

Aerospace & Defense: Lightweight interior aircraft components, avionics housings, cable management systems, connector shells, mounting brackets, and nonstructural precision plastic parts requiring performance-grade materials
Automotive & EV Components: Instrument panel components, electrical connector housings, sensor enclosures, fuse boxes, cable clips, fluid reservoir caps, HVAC ducting components, interior trim parts, and under-hood covers requiring heat and vibration resistance
Medical Devices: Syringe components, IV connectors, catheter hubs, diagnostic device housings, drug delivery device enclosures, surgical instrument handles, fluid manifolds, and single-use disposable plastic components requiring precision and cleanliness
Electronics & Electrical: PCB housings, wire harness connectors, switch housings, terminal blocks, circuit enclosures, strain relief components, and insulating barriers requiring tight tolerances and dielectric performance
Consumer Products & Appliances: Appliance housings, power tool bodies, ergonomic handles, storage containers, caps and closures, dispensing components, and protective covers requiring durability and cosmetic finish quality
Industrial Equipment: Machine guards, housing covers, brackets, knobs, levers, fluid system fittings, and structural support components designed for high durability and continuous use environments
Cosmetics & Personal Care: Lotion pump components, cosmetic compact housings, dispenser caps, closures, spray nozzles, and packaging components requiring chemical resistance and aesthetic quality
Construction & Agricultural: Pipe fittings, irrigation connectors, equipment housings, protective covers, tool components, and field-use plastic hardware designed for weather and impact resistance

Other

Tight-Tolerance Manufacturing

Precision molding processes ensure accurate, repeatable parts for demanding applications.

Material Versatility

Support for a wide range of engineering-grade thermoplastics.

High-Volume Production

Efficient processes designed for large-scale manufacturing with consistent quality.

Full-Service Capabilities

From prototyping to production and secondary operations, all under one roof.

Key Materials & Common Applications for Injection Molding

Key Materials for Injection Molding:

Polypropylene (PP): A lightweight, cost-effective, and chemically resistant material often used in packaging and consumer products.
Acrylonitrile Butadiene Styrene (ABS): Highly popular for electronics and consumer goods due to its stability, ease of molding, and good impact resistance.
Nylon (PA6, PA66, PA12): Strong, durable engineering thermoplastics often used in glass-filled formulations for high-strength, wear-resistant, and temperature-stable applications such as gears, housings, connectors, and automotive under-the-hood components.
Polycarbonate (PC): Used when high impact strength, transparency, and superior insulation properties are required.
Polyethylene (PE – HDPE/LDPE): Ideal for flexible, high-wear applications, such as caps, containers, and household items.
Polyether ether keton (PEEK): High-performance, high-temperature plastic suitable for specialized medical or aerospace components.
Polyetherimide (PEI): Excellent heat resistance, high strength, dimensional stability, and inherent flame resistance; commonly used in demanding electrical, automotive, aerospace, and medical applications.
Thermoplastic Polyurethane (TPU): Flexible, abrasion-resistant, offering excellent elasticity, impact strength, and chemical resistance.
Styrenic Block Copolymers (TPE-S / SBS): Flexible, rubber-like softness, good elasticity, and excellent processing ease.
Polyphenylene Sulfide (PPS): A highly chemical-resistant and thermally stable polymer used in aggressive environments, including automotive, electrical, and industrial components exposed fuels, solvents, and high heat.
Polyvinylidene Fluoride (PVDF): A high-performance fluoropolymer with excellent chemical resistance, UV stability, weatherability, and flame resistance. PVDF maintains strong mechanical properties in harsh environments and is commonly used for fluid handling components, electrical insulation, and chemical-resistant industrial applications.
Chlorinated Polyvinyl Chloride (CPVC): A thermoplastic produced by chlorinating PVC resin, increasing its chlorine content to improve heat resistance, chemical resistance, and flame retardancy. CPVC offers strong corrosion protection and higher temperature performance than standard PVC, making it suitable for industrial piping components, valves, fittings, fluid handling parts, and hot-water applications.

Common Injection Molding Applications:

Aerospace & Defense: Lightweight interior aircraft components, avionics housings, cable management systems, connector shells, mounting brackets, and nonstructural precision plastic parts requiring performance-grade materials
Automotive & EV Components: Instrument panel components, electrical connector housings, sensor enclosures, fuse boxes, cable clips, fluid reservoir caps, HVAC ducting components, interior trim parts, and under-hood covers requiring heat and vibration resistance
Medical Devices: Syringe components, IV connectors, catheter hubs, diagnostic device housings, drug delivery device enclosures, surgical instrument handles, fluid manifolds, and single-use disposable plastic components requiring precision and cleanliness
Electronics & Electrical: PCB housings, wire harness connectors, switch housings, terminal blocks, circuit enclosures, strain relief components, and insulating barriers requiring tight tolerances and dielectric performance
Consumer Products & Appliances: Appliance housings, power tool bodies, ergonomic handles, storage containers, caps and closures, dispensing components, and protective covers requiring durability and cosmetic finish quality
Industrial Equipment: Machine guards, housing covers, brackets, knobs, levers, fluid system fittings, and structural support components designed for high durability and continuous use environments
Cosmetics & Personal Care: Lotion pump components, cosmetic compact housings, dispenser caps, closures, spray nozzles, and packaging components requiring chemical resistance and aesthetic quality
Construction & Agricultural: Pipe fittings, irrigation connectors, equipment housings, protective covers, tool components, and field-use plastic hardware designed for weather and impact resistance

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