Injection moulding
At KB Components, we specialise in delivering high-quality injection moulding services tailored to meet the needs of diverse industries. Our state-of-the-art facilities, cutting-edge technology, and experienced professionals are dedicated to providing precise, efficient, and cost-effective manufacturing solutions. Whether you require small, intricate components or large, complex assemblies, our injection moulding capabilities ensure top-notch performance and reliability.
Injection moulding’s machine fleet
KB Components has more than 300 injection moulding machines, spread across ten distinct locations.
We offer:
- Injection moulding 25–3500 tonnes
- Injection compression moulding
- Compression moulding
- Back injection moulding on textiles
- 2K injection moulding 100–1000 tonnes
- Clean-room injection
- Clean-room assembly
What is injection moulding?
Injection moulding is a manufacturing process that produces parts by injecting molten material into a mould. This technique is ideal for mass production, enabling the creation of thousands, or even millions, of identical parts. While commonly used with thermoplastic and thermosetting polymers, injection moulding can also accommodate metals, glasses, elastomers, etc., making it a versatile solution for various manufacturing needs.
How does injection moulding work?
1. Mould design and fabrication
- The injection moulding process begins with the design and fabrication of the mould. Moulds are typically made from durable metals like aluminium or steel and are precision-machined to match the detailed features of the intended product. Using advanced CAD software, our engineers meticulously design the mould to ensure it captures every detail and dimension required.
- Single and multi-cavity moulds: Depending on your production needs, we cancreate single or multi-cavity moulds. Single-cavity moulds produce one part per cycle,whereas multi-cavity moulds can produce multiple identical parts simultaneously,significantly increasing production efficiency.
2. Material preparation
- Once the mould is ready, the next step involves preparing the material. The chosen material is fed into a heated barrel where it is melted. The heating process involves the use of heating bands and a helical screw that mixes the material to ensure it reaches a consistent molten state.
- Material selection: We work with a wide range of materials, including thermoplastics (like polyethylene, polypropylene, and ABS), elastomers, metals, and more. Each material offers unique properties, allowing us to select the best option for your specific application.
3. Injection and forming
- The molten material is then injected into the mould cavity under high pressure. This pressure ensures that the material fills every part of the mould, capturing the intricate details and complex geometries of the design. The mould is cooled to solidify the material, forming the final part.
- High precision and consistency: Our injection moulding machines are equipped with precise controls to maintain consistent temperature and pressure, ensuring uniformity and quality in every part produced.
4. Cooling and ejection
- After the material has solidified, the mould is opened, and ejector pins push the finished part out. The cooling process can be optimised using cooling lines that circulate water or oil, reducing cycle times and enhancing efficiency.
- Trimming and finishing: Excess material, known as flash, is trimmed off, and additional post-processing steps such as painting, coating, or assembly may be performed to meet your specific requirements.
Benefits of our injection moulding services
High production efficiency
Our streamlined injection moulding process allows for rapid production of large volumes of parts, making it ideal for mass production scenarios. The high level of automation minimises human intervention, reducing the likelihood of errors and increasing efficiency.
Precision and uniformity
We deliver parts with exceptional precision and consistency, ensuring each piece meets your exact specifications. Our advanced equipment and stringent quality control measures guarantee that every part is manufactured to the highest standards.
Versatile Material Options
We offer a wide selection of materials to suit various applications, from general-purpose plastics to high-performance engineering polymers. This versatility enables us to meet the specific needs of different industries and applications.
Complex part geometries
Our sophisticated moulding capabilities allow us to produce parts with intricate details and complex geometries. Whether you need components with tight tolerances, complex shapes, or fine details, we have the expertise to deliver.
Industries we serve with injection moulding
![Light vehicle - Volvo injection moulding](https://www.kbcomponents.com/wp-content/uploads/2024/07/Light-vehicle-169-featured.jpg)
Light vehicles
We specialise in manufacturing high-quality components for light vehicles, including interior trim parts, and exterior body panels. Our precision injection moulding ensures durability and aesthetic appeal for automotive applications.
![Light vehicle - Volvo injection moulding](https://www.kbcomponents.com/wp-content/uploads/2024/07/Heavy-vehicles-169-featured.jpg)
Heavy vehicles
![Light vehicle - Volvo injection moulding](https://www.kbcomponents.com/wp-content/uploads/2024/07/Medical-169-featured.jpg)
Medical
![Light vehicle - Volvo injection moulding](https://www.kbcomponents.com/wp-content/uploads/2024/07/Industrial-169-featured.jpg)
Industrial
![Furniture - injection moulding](https://www.kbcomponents.com/wp-content/uploads/2024/07/furniture-169-featured.jpg)
Furniture
Our injection moulding services for the furniture industry include the production of ergonomic and stylish components. We manufacture high-quality parts that contribute to the functionality and aesthetic appeal of modern furniture.
![Lighting - injection moulding](https://www.kbcomponents.com/wp-content/uploads/2024/07/Lighting-169-featured.jpg)
Lighting
We provide innovative solutions for the lighting industry, producing components that enhance the efficiency and design of luminaires. Our precision moulding ensures high performance and long-lasting quality.
![Lighting - injection moulding](https://www.kbcomponents.com/wp-content/uploads/2024/07/Chrome-plating-169-featured.jpg)
Chrome plating
We offer injection moulded parts ready for chrome plating, delivering aesthetically pleasing and corrosion-resistant components. Our services are ideal for automotive, decorative, and industrial applications.
![Industrial windows](https://www.kbcomponents.com/wp-content/uploads/2024/07/industrial-windows-169-featured.jpg)
Industrial windowS
Have a look at our industrial windows portfolio with several different versions and designs suitable for various applications and thermal zones.
Why choose KB Components?
Expertise and experience
With extensive experience in injection moulding, our team of experts is equipped to handle projects of all complexities, delivering superior results every time. We stay up-to-date with the latest industry trends and technologies to provide the best possible solutions.
Cutting-edge technology
We invest in the latest injection moulding technology and equipment, ensuring high-quality production and efficiency. Our advanced machinery allows us to produce parts with high precision and minimal waste.
Comprehensive quality assurance
Our rigorous quality control processes ensure that every part meets the highest standards of accuracy and reliability. We conduct thorough inspections at every stage of production to maintain consistency and quality.
Customer-focused solutions
We prioritise understanding of your needs and deliver customised solutions that exceed your expectations. Our dedicated customer service team is always available to assist you with any inquiries or concerns.
Start your project today
Ready to elevate your project with our top-tier injection moulding services?
Contact us today to discuss your requirements and receive a personalised quote. Let us help you bring your designs to life with precision and efficiency.
Choose us for unmatched quality and innovation in injection moulding services. Let us be your partner in success, delivering reliable and high-performance parts that meet your exact needs.