Maximizing Efficiency: The Importance of Assembly Capabilities in Injection Molding

When choosing an injection molder, product developers and manufacturers consider and weigh a myriad of factors, some of which may be unique to their organization. One important consideration for complex products is the assembly of the product components. Plastic injection molders can be categorized in two ways: those that offer assembly services and those that do not. Some large organizations may have the internal capabilities and resources to assemble in-house and may opt for a partner with limited capabilities to mold and ship components. For others, a partner with these capabilities is essential. Even those with in-house capabilities may benefit from injection molder assembly services. In this post, we specifically examine assembly services and the benefits companies receive when partnering with an injection molder that offers this capability.

The Processes

Many products are made from multiple components that are put together, so after injection molding and any secondary processes, the components are assembled. This can be as simple as snapping two parts together or as complex as creating a part from multiple components and attachment methods. Shipped parts may be subassemblies that are further assembled by the end-user or other person or complete parts that are used right out of the box.

Assembly may be manual or automated, which can include robotics. Manual automation is often reserved for more complex processes that require decision-making and flexibility. Simple repetitive assembly can often be automated.

Several assembly methods are commonly used to join plastic components, each with distinct advantages based on the part’s material, geometry, and application requirements. Popular methods include:

• Ultrasonic Welding: This method uses high-frequency ultrasonic vibrations to generate heat at the interface of two components to bond them together. It can create strong, permanent bonds without adhesives or mechanical fasteners.
• Snap-Fit Assembly: This method relies on molded features, like hooks or clips, to lock parts together mechanically without additional fasteners or adhesives.
• Spin Welding: Two thermoplastic components are joined by generating heat through rotational friction and pressure. The friction at the interface generates enough heat to melt the surfaces, and once the rotation stops and the part cools, a strong, permanent bond is created. This method can create hermetic seals for vacuum tanks or pressure vessels.
• Mechanical fasters: Components can be joined using screws, rivets, or pins, either with threaded inserts placed using insert molding or molded holes.

Design for Assembly

While the assembly stage comes near the end of the manufacturing process, it is important to plan for it early in the design phase. Design for assembly is an approach that, at a minimum, ensures the process will work (components will fit together and function as intended); however, it often considers ease of assembly, reducing the number of components, optimizing placement of hardware, ensuring assembly methods don’t impact structural qualities of the part, and more.

Design for assembly, followed by prototyping, can uncover potential issues, such as holes for fasteners not lining up or snap fits that don’t hold. Identifying and correcting issues early will increase efficiency and save money in the long run.

Benefits of Working with an Injection Molder with Assembly Capabilities

Partnering with an injection molder that also offers assembly services provides several key benefits:

• Streamlined production process: Combining molding and assembly with one partner makes the production process more efficient. This setup reduces the need to transport parts between different facilities, saving time and minimizing delays.
• Enhanced quality control: When one company handles both molding and assembly, it can better control quality throughout the process. This oversight helps identify and resolve issues early, leading to higher quality products.
• Cost efficiency: Consolidating operations can save money on transportation, labor, and overhead costs. A single supplier handling both processes can also offer more competitive pricing, reducing overall production costs.
• Improved communication and coordination: Working with a single supplier for both molding and assembly improves communication and coordination. A clear understanding of product requirements and timelines results in fewer misunderstandings and errors.
• Flexibility and customization: Injection molders with assembly capabilities are often more flexible and can tailor services to specific project needs. This flexibility ensures that the final product meets the customer’s desired specifications.
• Expanded capacity: For companies that typically perform in-house assembly, outsourcing assembly work to the injection molder opens up capacity and resources for other manufacturing activities. This is particularly helpful for new products that haven’t been tested in the market and when companies aren’t ready to invest in complete in-house manufacturing and/or assembly.

Deluxe Plastics’ Capabilities

Experience comprehensive assembly services in addition to injection molding when you partner with us. Whether you have simple sub-assemblies or complex, intricate assemblies, our facilities are equipped to handle all of your projects. We use advanced techniques and equipment to ensure precision and consistency in every product we assemble.

Our integrated approach to production and ISO 9001:2015 accreditation means we deliver complete, ready-to-use products that meet all your specifications. Contact us today to learn how Deluxe Plastics can streamline production and elevate the quality of your products.