Plastic Injection Molding

The ability to incorporate close tolerances and design intricacies makes injection molding one of our most popular and successful processes. From cell phones to computer components, injection molding is the process of choice for producing parts in large volume. Our state of the art capabilities allow for fast cycle times which leads to low cost parts for custom made pieces. Forte can handle the projects from the initial part design throughout the entire process of manufacturing and provide you with best shipping options. We feature an in-house tool maintenance program that helps minimize down time and maximize tooling life. Forte has injection presses ranging from 28 ton to 1,500 tons which allows us to handle a wide variety of custom injection molded parts. Our experienced staff can help you select the right material to best suit your application and we are equipped to handle long-run as well as short-run productions. 

Plastic Injection Molding Materials

Injection molding lends itself to the widest range of plastics in the industry:

○ ABS Injection Molding ○

    ABS INJECTION MOLDING
    Forte Products is a premier Midwest plastics manufacturer offering custom ABS injection molding services. ABS plastic molding is a great choice because it is somewhat inexpensive and also has such strong breakage resistance the product remains intact even upon impact. No matter the size or scope of your project, Forte has unique design ideas and equipment to complete the job affordably and efficiently. Our injection molding machines range in size from 28 to 1500 tons, allowing us to create plastic parts in many sizes, and molded shapes.

    WHY USE ABS FOR INJECTION MOLDING?
    One of the most commonly used materials in injection molding is ABS: Acrylonitrile Butadiene Styrene. ABS is a thermoplastic material known for its high impact resistance and toughness. Furthermore, it exhibits good resistance to scratching and rigidity with an excellent dimensional stability. ABS also works well in conjunction with metal coatings due to them being able to adhere strongly to ABS material. Due to its thermoplastic properties ABS is easily plastic injection molded. ABS has a low melting temperature and is also an inexpensive material.

    BENEFITS OF ABS INJECTION MOLDING
    • Cost
    • Platable and paintable
    • Strength and rigidity of the finished product
    • Strength to weight ratio

    ABS molded parts are used in a wide range of industries, such as manufacturing, automotive, medical, and marine. ABS is not recommended for food applications.

    SPECIFIC PRODUCTS WE HAVE MADE USING ABS INJECTION MOLDING:
    • Appliance manufacturing such as universal phone adapters
    • Parts to make automotive covers
    • Medical products
    • Marine products
    • Plastic Toys
    • Keys on a keyboard

    EXCELLENCE IN DESIGN
    At Forte, we pride ourselves on having upward of 40 years of experience in the U.S. injection molding business. Our commitment is to create and deliver a top-notch product according to your exact specifications as efficiently and cost-effectively as possible. Our knowledgeable staff is on call to assist you from design plans through production and shipping, and customizing our processes and materials to your needs is our specialty.

    NYLON INJECTION MOLDING
    Nylon injection molding is just one of the molding capabilities you’ll find at leading plastics manufacturer Forte Products. Our Kansas injection molding machinery ranges in size from 28 to 1000 tons, allowing us to manufacturer plastic parts of many sizes and scales. We are happy to discuss nylon injection molding ideas with each client to ensure the process and materials are an ideal fit for your project.

    APPLICATIONS FOR NYLON INJECTION MOLDING
    Nylon material is used in a large range of different industrial applications because of its impressive mechanical and electrical properties, excelling in toughness, wear resistance and chemical resistance.

    Nylon injection molding produces plastic parts that are used in countless industries and applications, such as:
    • Consumer apparel and footwear
    • Sports and recreation equipment
    • Industrial components
    • Medical products
    • Automotive products

    As nylon has great bending strength, it lends itself well for parts that will be intermittently loaded. Furthermore, with the high wear resistance and low coefficient of friction, nylon works well in applications such as slides, bearings and any device that is put through motion.

    NYLON PROPERTIES
    As a thermoplastic, nylon has a high level of heat stability, which contributes to its strength. The material is also resistant to a number of external factors, including:
    • Abrasion
    • Impact
    • Chemicals

    EXCELLENCE IN CUSTOM DESIGN
    Forte is a top U.S. injection molder committed to customization and superior craftsmanship. We work closely with our clients to ensure our nylon injection molding meets or exceeds your individual specifications. If nylon is not the right material for the job, we’ll discuss other injection molding options until we find the appropriate and cost-efficient design plan.

    POLYETHYLENE INJECTION MOLDING
    Forte entertains high volume production runs as well as low volume production runs with injection molding machinery ranging in size from 28 to 1000 tons. Depending upon your budget and application, polyethylene plastic may be the most economical material option for your next project.

    POLYETHYLENE PROPERTIES & DENSITIES
    In general polyethylene is light in weight and possess strength, chemical resistance, impermeability and impressive electrical insulating properties. Furthermore, the economic cost of the material makes it an excellent material for disposable and recyclable industrial product applications, whilst it's comparative low density enables more volume of plastic to be processed.

    Polyethylene is available in many different densities:

    • High density polyethylene (HPDE) – a food-grade plastic.
    • Low density polyethylene (LDPE) – the first grade of polyethylene to use a high-pressure process with free radical polymerization.
    • Linear low-density polyethylene (LLDPE) – differs structurally from LDPE because it has short branches and LDPE has long chain branching.

    The higher the density of the polyethylene material used the stronger, more rigid and more heat resistant the plastic is. The higher density models show better properties in tensile strength, chemical and heat resistance, surface hardness and abrasion resistance. HDPE for injection molding works well in both hot and cold temperatures and has a tensile strength of 4550 pounds per inch.

    BENEFITS OF POLYETHYLENE
    • High levels of ductility
    • Tensile strength
    • Impact resistance
    • Resistance to moisture absorption
    • Recyclable

    INDUSTRIAL APPLICATIONS OF POLYETHYLENE
    The versatility of the polyethylene makes the material an ideal choice for the following industries and products:

    • Agricultural products
    • Lawn and Garden products
    • Heavy construction
    • Consumer products, including toys, food containers and garbage receptacles
    • Plumbing products
    • Medical products

    POLYPROPYLENE INJECTION MOLDING
    Polypropylene, sometimes referred to as pp, is a synthetic resin used in our injection molding for a wide range of applications. Polypropylene is one of the lowest density plastics; the density ranges between 0.895 and 0.92 g/cm. Polypropylene is safe for use as food containers because polypropylene does not leach chemicals into food products. Trust Forte for all your polypropylene injection molding needs. Forte Products offers a variety of plastic polypropylene injection molding services to create parts and products of all shapes and sizes. Our fleet of injection molding equipment ranges from 28-ton machinery for smaller components to 1000-ton machines suitable for large parts.
    Polypropylene is used in lots of other applications including; household goods, automotive products, marine and RV products. Below is a list of some of the benefits of choosing polypropylene for your molded plastic parts:

    WHY USE POLYPROPYLENE FOR INJECTION MOLDING?
    • Excellent moisture resistance
    • Mold in or “living hinge” capabilities
    • Food grade availability
    • Excellent impact strength
    • Chemical resistance
    • Low cost

    Forte has been in business for over 60 years, and understands that there is no “one size fits all” solution when it comes to the production of molded plastic parts. We’re here to see you through the design process, manufacturing of your item and delivery—in the way you specify. Our goal is to provide clients with high-quality, cost-efficient products to suit their unique application. We offer not only injection molding, but a wide range of fabrication options; please visit our molding capabilities for more detail.

    • Vacuum forming
    • Rotational molding
    • Plastic blow
    • Plastic machining

The Plastic Injection Molding Process

A chosen plastic pelletized material is melted down in a the machine’s heated barrel to create a liquid state. This molten liquid material is then forced into the a mold cavity by either a screw or ram injector which are used to control the pressure of the injection.
The injected molded parts cool and harden into a solid form to the configuration of the cavity. 

Applications of Injection Molding

Injection molding is the most common process of parts and components manufacturing and it is ideal to produce high volume of the same part. Example of its applications can be found in:

Aerospace & automotive components

• Cable assemblies
• Computer electronics
• Hydraulic and Fuel Tanks
• Instrumentation
• Medical & dental products
• General consumer goods
• Bottle lids & caps

Benefits of Plastic Injection Molding

High production rates Low labor costs All used materials and scrap can be reused
Little or no post-production work required
○ Close tolerances and intricacies can be achieved on the parts
Custom design and molding to meet specific applications 

Upper Catcher Chute Tube

Traction Boards

Raptor Catcher Lid

Hinge Assembly

Chute Discharge