The cost of medical injection molding for manufacturers ranges between $10,000 and $100,000. These costs depend on the number of orders, the type of material used, the pattern of molding, and other factors. Among these several factors, some common ones include the type of material used, the part’s complexity, the number of cavities, and the size of the run.
Usually, the costs of medical injection molding range from $10,000 to $100,000 depending on the quantity of the order and the parts to be molded. While medical injection molding may be costly initially, but it’s relatively cheaper in the long run, mainly when producing large quantities of products. The following are some of the factors that influence the final price of the product: the cost of the resin, tooling cost, time required to complete the production cycle, mold capacity, and other specifications.
Most commonly used plastic resins for medical injection molded products
The most popular material used in plastic medical injection molding is plastic resins, and the cost of these resins ranges from $. From 90 cents to over $2 per pound. Other factors that affect costs are heat stabilisers or plasticisers that may be employed in the process. Here are vital factors to consider when choosing a resin:
- Intended Use: This is important because it defines the characteristics of the base material and how it will interact with the other components of the composite material.
- Chemical and environmental resistance: Ensure the durability and how long the material will last in various environments.
- Appearance: Consider the end product’s density, hue, and transparency.
- Part Longevity: Learn how long the molded part will last.
The plastic resin prices vary depending on the intended type used. In general, pellets are used mainly in molding. For example, POM and PC are categorized as relatively expensive engineering plastics. Buying in large quantities is cheaper since the producers and distributors offer their products at more affordable prices when sold in large quantities.
ABS (Acrylonitrile Butadiene Styrene), is usually used in computer keyboards and faceguards on wall sockets due to its strength and it is also recyclable. It’s priced at $1—30 per pound.
PE (Polyethylene) is extensively used in packaging materials, grocery bags, and cable insulation and is manufactured in tens of millions of tons annually. It’s priced at $1. It costs $20 per pound and is employed in different uses, including in producing electronics and automotive parts.
PP (Polypropylene) is used in packaging, textiles, and automotive applications due to its good electrical properties and low moisture absorbability. It costs $0.90 per pound. Because of its high impact strength, PC (Polycarbonate) is used in agriculture and electrical equipment that needs safety features, barriers/fences, and storefront protection. It’s priced at $2—30 per pound.
PS (Polystyrene) is used for laboratory ware, food packaging, and gardening equipment because it is inert and can be used for solid parts. It costs $1.00 per pound.
POM (Polyacetal) is an engineering thermoplastic used in precision parts and automotive components due to its stiffness, stability, and low friction. It costs $2—20 per pound.
Plasticizers and mineral fillers are the most affordable additives, while lubricants and heat stabilizers can be more costly. Some additives include glass fiber, ceramic fillers, pigments, UV stabilizers, plasticizers, and antioxidants, which can improve the properties of the resin, such as strength, impact strength, durability, and color.
Labor & Other Services Expenses
In medical injection molding, labor costs encompass several key areas:
- Setup Costs: Every step of the medical injection molding process involves specific setup parameters, particularly during mould-making tooling setup. This process requires technical skills and accuracy, adding to setup costs.
- Repair Costs: Due to the mechanical nature of plastic medical injection molding and the various equipment used, parts may wear out or malfunction over time. Maintenance and repair activities are also crucial, contributing to the total expenses.
- Operator Costs: Medical injection molding machines are mostly automated, but an operator constantly supervises the process. Operating costs are thus essential factors in labor costs.
Cost of Injection Molded Parts
Several factors affect the cost of injection-molded parts, such as the cost of maintaining the mold, the time to produce the parts, and the material used. This includes the production rate, the expected percentage of scrap, the weight of the material, and any extra charges for mold maintenance or guarantee. Other factors that should be considered in the quoted price include mould setup costs.
Time Required To Complete Medical Injection Molding Process
The time taken to complete the medical injection molding process is a major determinant of the cost of the final part. This time is when the material is injected into the mold and the cooling time determines the quality of the part as it cools and shrinks. Machines in manufacturing companies have standard hourly charges that are added to the cost of production.
Tips to Optimise Medical Injection Molding Costs
- One of the simplest ways to decrease medical injection molding costs is to increase the number of parts. This distributes the costs of mold design and machining over more parts, lowering the final price per part.
- Another effective strategy is to use Design for Manufacturing (DFM) analysis. This entails developing part designs that are optimized and cost-effective. Due to the consideration of factors such as technology, art, and science, DfM helps to minimise the cost of medical injection molding while at the same time meeting the intended purpose of the part. This way, you can reduce mold and production costs by eliminating features that are not essential to the part’s function or by reducing cosmetic features that are not necessary.
- They should be used if the project can be done using universal molds instead of custom molds. While universal molds are slightly more expensive, they can still create high-quality parts, which makes them a good solution for reducing medical injection molding costs.
- Another crucial factor is optimizing material selection. Selecting cheaper materials such as ABS or polypropylene, while not affecting the quality of the parts, can help cut overall costs by a large margin while maintaining the necessary performance levels.
- Insert molding or overmolding can also save costs, particularly for parts that require attachment to metal parts. These techniques help save time and energy that would otherwise be used in other fastening processes, making manufacturing cheaper.
- Reducing the number of cavities in your mold can also significantly reduce the cost of manufacturing the part while retaining its functionality and look.
- Self-mating parts are a reliable method of reducing medical injection molding costs and reducing design complications. These parts engage with each other when rotated 180 degrees, which means that only half of the mold is required, thus cutting the mold expenses, and making the injection mold smaller.
Summary
Today, medical injection molding is one of the most used techniques for manufacturing many products. Understanding the costs of medical injection molding and how they are calculated is crucial in improving the manufacturing process. This article provides information on what influences these costs and how this information can be used effectively. It is vital to comprehend the costs associated with injection mold tooling and molds to make the right decisions in manufacturing.
FAQ’s
Q1. Is medical injection molding pricey?
It is not a clear-cut answer. However, the cost of medical injection molding can vary depending on the part complexity, production volume, and time required to bring to markets. For example, producing many of the same products at once can make medical injection molding affordable.
Q2. Is medical injection molding part fabrication expensive?
The cost usually ranges from $100$ to $1000$. The exact cost of medical injection molding is difficult to identify since it is used for various products.
Q3. Is it possible to use medical injection molding with materials other than plastic?
Yes, medical injection molding is often used with thermoplastics and thermosetting polymers, but it can also work with metals and elastomers.