Understanding the roles that different plastic manufacturing processes play throughout the manufacturing landscape can help OEMs and other potential customers know which production methods might be best suited for their next line of components and products.

Port Erie Plastics’ guide to different plastic manufacturing processes is a comprehensive overview of the methods themselves, key benefits of production, and top considerations to make before selecting a specific process.

Key Benefits of Different Plastic Manufacturing Processes

Port Erie Plastics has three different forms of plastic manufacturing processes we perform in our facilities: injection molding, plastic extrusion, and structural foam molding. These three services are the ones we’ll focus on here.

Benefits of Injection Molding

• Injection molding is a highly repeatable process once the mold design has been finalized and properly tooled. Molds can be used over and over again as long as they are properly maintained.
• Additionally, since the process is highly repeatable, it is also a fast production method.
• High-volume production orders are best suited for injection molding as the cost-per-part ratio drops dramatically after tooling costs.
• Since melted plastics are shot into the mold and it takes the shape of the mold, complex designs are possible through injection molding.
• Minimal waste is created through injection molding as it is an additive process rather than one that involves trimming material into a shape.

Benefits of Plastic Extrusion

• Plastic extrusion is often viewed as one of the most cost-effective plastic manufacturing processes on the market because of the use of automation in the process and the ability to create continuous shapes.
• Extrusion is the choice for many OEMs and other customers when they need parts that include cross-sections.
• Multiple materials can be used in a singular extrusion run (co-extrusion), blending materials and leading to further enhanced parts.
• Extrusion operations use highly efficient thermoplastics that can be reused over and over again, leading to material efficiency and minimal waste.
• Parts made through extrusion feature consistent high quality.

Benefits of Structural Foam Molding

• Parts created through structural foam molding traditionally boast a higher strength-to-weight ratio compared to other plastic manufacturing processes.
• In low-pressure structural foam molding, less clamping force is required during manufacturing, which can make it a more cost-effective solution.
• Structural foam molding is best suited for large part manufacturing.
• Structural foam molding can create parts with enhanced performance, specifically chemical, impact, heat, and weather resistance.
• The process creates minimal defects, such as sink and warpage.

Considerations Before Selecting a Manufacturing Process

After viewing the benefits of the different plastic manufacturing processes, these advantages are the guiding principles when selecting a production method. But let’s break it down further.

Select Injection Molding If

Your team needs fast turnaround times where the manufacturing process features fast cycle times. Parts created through injection molding are best suited for high-volume production as the cost-per-part ratio drops quickly, offsetting the tooling costs.

Select Plastic Extrusion If

Your team needs continuous shapes that feature simple or complex cross-sections that are integral to the overall structural integrity of the part.

Select Structural Foam Molding If

Your team needs parts with a higher strength-to-weight ratio and complex geometries that are going to serve in demanding environments. Additionally, if your team needs lower production costs and large part sizes, structural foam molding can align well with your end goal.

Best Applications of Different Plastic Manufacturing Processes

With benefits and considerations covered, the most direct way to showcase which manufacturing process is best for your team is by listing out real-world applications of each process.

Applications of Injection Molding

• Dashboard components in the automotive industry
• Bumpers
• Laptop enclosures
• Mobile phones
• Tubing connectors in the medical industry
• Syringes
• Caps and closures

Applications of Plastic Extrusion

• PVC pipes
• Siding
• Window frames
• Weather stripping
• Plastic films
• Gaskets

Applications of Structural Foam Molding

• Reusable pallets and containers
• Large waste bins
• Point of sale machines
• Kiosks
• Display racks
• Large panels

Contact Port Erie Plastics for All Your Plastic Manufacturing Needs

Port Erie Plastics opened its doors in 1953 with a single injection molding machine, and over the course of 70-plus years, we’ve expanded our capabilities into a multi-faceted plastic manufacturing company.

We’re able to perform different plastic manufacturing processes because of the relationships we’ve built with our customers, allowing us to adapt to their industries and invest in the knowledge and infrastructure necessary to produce the components they need, when they need them. No matter which manufacturing process we’re performing, all of our production methods are backed and vetted by our ISO 9001 certification, which demonstrates our quality management systems.

Whether it’s injection molding, plastic extrusion, structural foam molding, or one of our other capabilities, Port Erie Plastics is ready to take your project on. Contact our team today.