You want to develop a plastic product that not only functions, but is also seamlessly scalable. However, the injection molding process often feels like a black box. What happens between design and series production? In this blog, we explain it clearly for you. Want to translate this directly to your product? Then schedule a brainstorming session with Maick.
In this blog, we give you control: the entire process in 6 clear steps.
Step 1: Design & engineering: from idea to manufacturable design
Everything starts with the design. Often, there is already a 3D model on the table that seems perfect from a functional or aesthetic perspective. In this phase, we add an extra lens: manufacturability. We look at how the product will fill, cool, be ejected, and assemble with other parts.
We assess, among other things:
- Wall thicknesses, ribs, stiffeners
- Drafts, gate locations, radius transitions
- Assembly with other components
With Design for Manufacturing, we make sure your design will come flawlessly out of the mold.
Step 2: Material selection: the backbone of your product
The best design will fail if the material is not right. In this step, we translate your functional requirements into a specific plastic: what must the part really be able to withstand in practice?
We discuss questions like:
- Will the product be used outdoors (UV, temperature, moisture)?
- Does the part need to be impact resistant or rather stiff and dimensionally stable?
- Are there requirements regarding food contact, medical application, or fire safety?
- Is there a sustainability ambition (recycled, biobased, multiple life cycles)?
Based on this, we advise on traditional plastics (e.g., ABS, PC, PA) and biobased or recycled options. We look not only at the properties on paper, but also at processability, production stability, and availability. This way, you get a material choice that is technically correct and suits your sustainability goals.
Step 3: Prototype & validation
Before you have thousands of pieces produced, you want to be sure your design works. That’s why we use 3D printing as an accelerating intermediate step. We print prototypes that in terms of shape, fit, and sometimes also function are very close to the final injection molded part.
With these prototypes, you can:
- test fit and measure in the complete assembly
- test how the part feels in hand or is operated
- involve internal stakeholders and customers in the design
- collect early feedback from production, service, or sales
Any issues—such as a hard-to-reach snap connection, interference with another part, or an illogical radius—can still be easily addressed in the 3D model at this stage. Only when the design has been validated in practice do you move to steel. Less risk, more certainty.
Step 4: Mold production & testing phase: from digital to steel
Now that the design is finalized, we translate it into a mold that can produce this part thousands of times exactly the same. In the detailed engineering, we determine the final gate locations, cooling, and ejection system. With Moldflow simulations we predict the fill and shrinkage patterns and make adjustments where needed.
Then the actual mold building starts in our factory. As soon as the mold is ready, the first test shots follow (T0/T1). In this testing phase, we check:
- dimensions and tolerances
- shrinkage, warpage, and any stresses
- surface quality and visual zones
- functionality of snap connections, hinges, and fits
Based on measurement reports and your feedback, we perform fine-tuning. Only once the product meets the agreed specifications do we release the mold for series production. So you do not go in “blind,” but based on measurable data.
Step 5: Series production & assembly: scalable output
After approval, the injection molding machine truly starts working for you. We record process settings (temperatures, pressures, cycle times) and secure these in work instructions, so every batch is produced repeatably. Our energy-efficient machine park plays a role: stable processes, with less energy consumption.
Depending on your needs, we can:
- supply individual components in bulk
- perform simple to complex assembly
- post-process parts (e.g., drilling, tapping, printing)
- pack according to your logistical requirements (per set, per box, labeled)
The result: a stable production process that adapts to your demand. Scaling up to higher volumes does not require a new chain, but simply scaling up within the same process.
Step 6: Logistics & aftercare: continue and further develop
After production, the logistics part begins. We make clear agreements about delivery times, stock strategies, and packaging method. Think about safety stock, call-off agreements, or Just-in-Time delivery to your assembly line.
But it doesn’t stop at delivery. In the aftercare phase:
- we evaluate the first series and any field feedback
- we look for optimizations in cycle time, material use, or design
- we discuss future variants or product families
Your product thus becomes not a static endpoint, but a platform you can continue to build on. And you keep one partner who knows the complete picture: from first idea to the last optimization round.
How long does an average injection molding process take from idea to production?
That depends on complexity, but generally you should expect a few weeks to a few months, including design, prototypes, mold construction, and validation.
Why is Design for Manufacturing so important in injection molding?
Because you already prevent issues with draft angles, shrinkage, deformation, or assembly in the design. Designing well early saves a lot of time and money.
Do I always need a prototype before the mold?
It is not required, but highly recommended. With a 3D-printed prototype, you can test fit, function, and ergonomics before you invest in steel.
Who safeguards quality during the injection molding process?
A good partner works with fixed measurement plans, test reports and quality controls per batch. This way, as an engineer, you know that every product remains within specifications.
QDP as guide through the process
For engineers, the most important thing is predictability. That’s why we work with a fixed structure, clear communication, and transparent planning.
Want to know what this process looks like for your product idea? Schedule a free brainstorming session with Maick Klaassen and walk through your ideal route in 30 minutes.