Keyflex provides precision plastic injection moulding solutions for a wide range of industries, delivering high-quality components tailored to your product requirements. Our plastic injection moulding capabilities support both prototype development and low- to high-volume production, helping customers achieve consistent quality, reliable performance, and cost-effective manufacturing.
Our team works closely with customers throughout the design and manufacturing process to ensure every component meets the required technical and visual specifications. From initial concept and 3D CAD files through tooling, mould production, testing, and final manufacturing, Keyflex provides a complete plastic injection moulding service.
Plastic injection moulding is an effective solution for producing complex components with repeatable dimensions and consistent finishes. It is suitable for electronic housings, enclosures, control panel components, keypad parts, covers, brackets, and other customised plastic products. By selecting the appropriate material and mould design, components can be manufactured to provide the required strength, flexibility, durability, and resistance to environmental conditions.
Successful injection moulding starts with careful product design. Several important factors need to be considered during the design and tooling stages to avoid manufacturing problems and ensure the final component can be produced efficiently.
Draft Angle:
Adequate draft angles allow the moulded component to be removed from the mould smoothly without damaging the part or mould surface. The required draft can vary depending on the material, surface finish, and texture.
Undercut:
Undercuts can make mould release more complicated and may require additional tooling features such as slides or lifters. Identifying undercuts during the design stage helps minimise tooling complexity and production costs.
Wall Thickness:
Wall thickness should be carefully controlled throughout the component. Walls that are too thick may cause sink marks, shrinkage, or longer cooling times, while walls that are too thin can affect strength and mould filling.
Sharp Steel:
Sharp steel areas within the mould require careful consideration because they can affect tooling durability, component release, and manufacturing quality. Appropriate design helps maintain reliable mould performance.
Shut-Off Areas and Texture:
The draft angle of shut-off areas and the selected surface texture can influence mould construction and part quality. These details should be reviewed before tooling begins.
Shrinkage:
Plastic materials naturally shrink as they cool. Material-specific shrinkage rates must be considered when designing mould dimensions to ensure the finished component meets the required specifications.
Miscellaneous Issues:
Other factors such as material selection, parting lines, ejector locations, gates, cooling, tolerances, and cosmetic requirements should also be considered. Early design review can help identify potential manufacturing issues before tooling investment.
With extensive manufacturing experience and integrated tooling capabilities, Keyflex can help customers develop practical, reliable, and production-ready plastic components. Our goal is to deliver precision injection moulded parts that provide consistent quality and dependable performance across a wide range of applications.
