Our Services

QUALITY FROM START TO FINISH

PLASTIC PART DESIGN

Nowadays, injection molding is one of the most popular methods of manufacturing plastic parts. They are used in automotive parts, electronic housings, household appliances, medical equipment, bicycles and many others. Designing 3D parts is an essential step in creating a successful product that meets both the manufacturer’s goals and the needs of the final user. It involves balancing technical, economic and aesthetic requirements with the specific requirements of the user. There are several factors that must be considered when designing plastic components to make them possible to launch and to ensure that the injection molding process works properly.

KEY FACTORS INCLUDE:

• material considerations for the intended application (temperature, chemical resistance)

• wall thickness

• draft angles

• corner radius

• gate position

• inclusion of ribs and protrusions

• material shrinkage

• special features (holes, undercuts)

These design features must be considered to produce the best injection molded part. Attention to critical part and mold design details enable us to produce repeatable quality parts. Before beginning your project, we work with you to complete our product requirements and design specifications questionnaire. This valuable document covers key elements including product usage and function.

NEED TO ANSWEAR SOME SAMPLE QUESTIONS:

• How will you use the part? What is its application? Is it a standalone product or a component of an assembly?
• What is the user environment (UV exposure, salt water, corrosive chemicals)?
• Does the part need to withstand specific pressure or impact?
• What is the target weight, dimension, texture, color, and aesthetic design?

The design of a plastic part is the first and most important step in our concept for manufacturing solutions. Our design process and feature checklist are a regular part of our engineers’ work. Attention to critical details of part and mold design enables us to produce repeatable, high-quality components that meet our customers’ requirements and are optimized for success.

WHAT IS MOLDFLOW 3D FOR?

The design of injection molded parts is optimized using injection molding simulation software such as Moldflow 3D. Using simulation during the design phase can help reduce physical mold issues. It allows the designer to modify and re-simulate the design to implement improvements. The mold tool should be designed so that the plastic part slides out easily. Working with an experienced plastic injection molding and engineering team can help avoid many of the issues that may arise during the design and development process. ALKAZ Plastics’ experienced design team understands the importance of this process and works closely with customers to determine product design specifications. By working with customers, we ensure that the final product meets their specific requirements and is optimized for success.

MOLD BUILDING

Engineering success is determined by our ability to maximize success, and we know for injection molded plastics, the engineering and design development process is critical. We’ve found that the two most critical factors for success are partnering with you early on in the design phase and focusing on what we consider the 5 Keys to Success. The following five stages must work together to engineer out cost and engineer in part quality and performance.

5 STAGES:

1. Part Design and Material Selection. Understand the product application, intended market, end-use objective and use environment.

2. Tool Design and Mold Building, Design for mold efficiency, longevity and performance.

3. Molding Process. Review injection molding technologies, cycle times and material flow, and employ scientific injection molding.

4. Quality Systems and Metrology. Focusing on tolerances, part inspection, steel safe mold and more.

5. Automation Systems.

A successful part starts with a well-designed mold. This complex and precise process determines part manufacturability and lifecycle costs, and it takes into account the key components of mold design while adhering to a part’s unique specifications. Proper mold design and mold building will help reduce cost, increase quality and optimize performance. We use the latest CAD technology and software to create a robust mold design, as well as moldflow analysis to evaluate all mold designs and parts prior to development.

HIGH PRECISION

ALKAZ Plastics’ team of mold design experts has decades of experience building custom and technically advanced molds. We produce high-quality injection molding tools using the latest technology for maximum performance and durability. We work closely with our customers throughout the design process to ensure mold design specifications align with product design goals and manufacturing requirements. Our mold design process incorporates the latest technology and industry standards, ensuring molds are optimized for maximum performance and durability. At ALKAZ Plastics, we are committed and focused on meeting the unique needs of your plastic parts production. We will support you through every stage of the design process, then quickly and accurately implement your manufacturing project.

MOLD TRIALS & QUALIFICATIONS

All new plastic injection molds undergo mold trial and qualification to ensure all part dimensions are correct and the mold functions properly. Scientific injection molding is then used to establish consistent and repeatable molding process parameters, which ensures quality parts are produced. All part dimensions are then reviewed for accuracy.

PRODUCT DEVELOPMENT

Start the process of bringing your design to life with us. Turn your 2D sketches into 3D computer-generated models. Our team of CAD and graphic designers have years of experience bringing product concepts to life. The ALKAZ Plastics team is dedicated to product design and development. They will provide high-quality, photorealistic images for marketing and concept testing. Designing a product for production from the start not only ensures quality but also saves our customers time and money. As a full-service development company, we review every aspect of the design, from the smallest component to the plastic casing. We have years of experience designing products for easy production. Our facility’s prototyping services include CNC and 3D printed parts, prototype assembly for testing and short-run production. We produce prototypes for engineering validation. We can also produce a full working model for use at trade shows or demos. Rapid prototyping provides the critical feedback you need to confirm and finalize your product design process.

CONSTRUCTION DEPARTMENT

CRUCIAL ISSUES:

WE SUPPLY TO VARIOUS INDUSTRIES

INJECTION MOLDING OF PLASTIC PARTS

Plastic injection molding process is a cost-effective way to create plastic parts in low to high volumes. It involves injecting molten plastic material into a mold cavity, allowing it to cool and solidify, and then ejecting the finished part from the mold. ALKAZ Plastics provides custom plastic injection molding services, expert engineering support, and detailed consultations to ensure your specifications are met. Our capabilities include DFM feedback and fast turnaround times for low and high volume production runs. We produce parts ranging in size from 1 gram up to 800 grams.

Our experience, along with the latest innovations in custom plastic injection molding technologies, has provided us with a competitive advantage on each and every project.

CAPABILITIES:

Horizontal plastic injection molding
Vertical plastic injection molding
Large parts
Molded-in color
In-mold decorating and labeling
Overmolding
Insert molding
Two-shot molding (2K)

PLASTIC INJECTION MOLDING 

ALKAZ Plastics offers design, engineering, tooling and post-processing services. We offer cost-effective, high-volume plastic injection molding, creating high-quality parts for diverse industries. Plastic injection molding produces plastic products by melting plastic and injecting it into a mold cavity. The liquid mixture then fills the volume evenly and crystallizes to form the desired shape. Thanks to this method, it is possible to achieve high quality in products from a wide variety of fields. To implement the technology, complex and expensive equipment is used, which ensures high productivity.

We produce top-tier injection moulded plastic components for a wide variety of plastic products. These include consumer electronics, automotive interior trim, precise medical devices, plastic parts with high surface requirements, beauty device components, massager parts, watch plastics, electronics plastics, and more.

LARGE PARTS

When molding large parts, the little details become even more important. At ALKAZ Plastics, the right infrastructure, innovation and expertise come together every day to produce high-quality, cost-efficient parts. Focusing on fit, form and function ensures we exceed our customers’ expectations and requirements throughout long-term part production. Today, we operate several large-ton plastic injection molding machines, ranging from 1000 to 2100 tons, at our facility.

MOLDED IN-COLOUR PLASTIC INJECTION MOLDING

Color is a critical part of many plastic injection molded components, and molded-in color technology enables vibrant, long-lasting, high-quality color and finish without the cost or environmental concerns of painting or plating. With molded-in color technology, pre-colored plastic resins are used in the plastic injection molding process, so the molded part emerges in the specified color and finish. This process eliminates painting, plating or other finishing steps. The color is fully integrated into the component, eliminating quality issues due such as paint scratching or peeling.

IN-MOLD DECORATING AND LABELING

We have extensive experience with all types and sizes of custom plastic in-mold decorating and in-mold labeling and continue to develop specialized solutions with this technology for a wide range of industries and applications.

INSERT MOLDING

Nowadays, many products are made as a combination of metal and plastic parts. There are many reasons why insert molding is such a popular process. The relevant adventage among them is its cost-effectiveness compared to other inserting processes. Besides, it provides a reliable and strong attachment point for inserts, thereby improving the overall strength of the component. Insert molding is an injection molding process that involves adding inserts, particularly metal ones, into an injection-molded part. Placing the insert within the mold cavity occurs before molten plastic injection. Consequently, on cooling, the insert becomes a permanent plastic part.

Insert molding facilitates the manufacturing of strong, durable, and lightweight parts, which is why several industries are adopting this process. Besides, the metal inserts strengthen the mechanical properties of plastics  used during the insert molding process.

OVERMOLDING

Overmolding is an advanced plastic injection molding technique used to connect two or more thermoplastic materials into a single, unified part. This process begins by injecting the first thermoplastic, known as the substrate, which forms the core structure of the product. A second material, called the overmold, is then injected either around or onto the substrate, bonding with it as the materials cool. The overmolding technique enhances the durability, functionality, and aesthetics of products, commonly used in high-volume production for industries that require high-performance parts, such as automotive, medical devices, and electronics. At ALKAZ Plastics, we specialize in custom plastic overmolding to boost the functionality and visual appeal of your components. Our expert team and advanced technology deliver seamless connections between materials, ensuring top-quality results.

TWO-SHOT MOLDING (2K)

SECONDARY SERVICES

Being present  in the market for over 30 years, we can  definitely say that we know how to implement our Clients’ projects effectively. Moreover, we are constantly developing the scope of our services, the quality of produced components and the level of service. We are continously looking for niche services and innovative solutions to fulfill our Customers’ visions and ideas even the most sophisticated ones. Responding quickly to our Clients’ needs and providing them excellent after-sales service is the key to building long-lasting relationships.

ULTRASONIC WELDING

Ultrasonic welding is an innovative technology for connecting plastics, metals, and fabrics, which uses the energy of ultrasound to create permanent connections between materials. Ultrasonic welding is an innovative technology that is used in many industries i.e. in the automotive industry it can be used to connect bodywork elements, or in the electronics industry to put together various electronic components, such as integrated circuits, printed circuits, or semiconductors.

Its ability to create durable, precise, and aesthetic connections makes it an attractive solution for manufacturers looking for effective methods of connecting different materials. Thanks to the continuous development of this technology, we can expect an increasingly wider use of ultrasonic welding in industry in the future.

HEAT-SET INSERTS

Heat-set inserts create a significantly stronger pull-out and torque-out rating of the resulting thread, compared to other types of inserts, to establish a more secure bond.

PAD PRINTING

Pad printing is a modern printing technology used to apply patterns and 2D images to all kinds of 3D objects. The pad printing machine is relatively small and equipped with a flexible silicone cushion, the so-called pad, which tamps the paint from the embossed form onto the surface of the object. Using pad printing, patterns can be applied to various materials such as plastic, metal, glass, ceramics or wood.

This technology has many applications in various industries, including in the electronics industry to apply markings to the housings of electronic devices.

Pad printing is very precise and allows for the application of details even on small objects. It is also perfect for printing on irregular surfaces. Modern pad printing machines are equipped with advanced control systems that ensure excellent quality and repeatability of patterns.

PLASTIC SURFACE FINISHING

Surface finishes can enhance the appearance, improve the feel of a surface, or provide additional functional properties to plastic parts. Finishes are available in smooth or polished, semi-gloss, matte, and textured finishes.

The plastic surface finishes table provides clear information on the different surface finishes. As we know, choosing the right injection molded surface finish for your plastic product has several advantages. However, you need to do this as early as possible in the design process. This is because the surface finish will impact the machining process and other decisions. Therefore, it is helpful to work with a plastic injection molding expert who can help you understand the table and ensure that you make the right choice.

ASSEMBLY & PACKING

Packaging and assembly are the processes carried out after or during the manufacturing process. It involves the use of a human or machine to assemble components according to the customer’s specification and package them appropriately for safe transport.

Assembly methods available:

– insert molding

– overmolding

– ultrasonic welding

– heating

– sealing with some string

We can supply complete sub-assemblies or complete products. This can include packaging the product and implementing a custom packaging. In addition, we can deliver the complete product in bulk directly to your customer. Our packaging and assembly is tailored to your individual requirements. We are open to discussions on the best way to deliver your product to you in the most efficient way possible.

ASSEMBLY

At ALKAZ Plastics we not only manufacture plastic parts, but also we provide several methods of assembly for instance:

– assemply of brass, stainless and steel inserts by

– ultrasonic welding

– heating

– pressing

– overmolding

– insert molding

ULTRASONIC WELDING

At ALKAZ Plastics we use ultrasonic welding in mass production. That is a fascinating technology that combines science and engineering to join materials without the need for extra adhesives or fasteners. By using high-frequency ultrasonic acoustic vibrations, we can bond workpieces together under pressure.
This technique is incredibly efficient and versatile, making it ideal for both plastics and metals.

INSERT MOLDING

Insert molding has become popular in plastic injection molding, being a unique way to combine the mechanical properties of plastic and metal for much stronger components. This technology is an excellent way to reduce assembly time and costs, increase the design flexibility and reliability, and reduce size and weight of the final product. Insert molding is a process that involves molding thermoplastic material around a brass, stainless or steel insert to create a completed part with multiple materials. Commonly insert molded parts include dials, metal threads and electronic housings.

One of the key advantages of ultrasonic welding is that it allows for the joining of dissimilar materials, creating strong, reliable bonds. This is particularly beneficial in industries like automotive, consumer electronic and the medical industry, where different types of materials need to be seamlessly integrated.
Additionally, the process is fast, efficient, and can be easily automated, which is a major plus for mass production.

PACKING 

Oferujemy usługę pakowania produkowanych przez nas wyrobów zgodnie z indywidualnymi wytycznymi Klienta:

– w opakowania detaliczne i zbiorcze

– naklejanie etykiet, naklejek, kodów, hologramów

– wkładkowanie ulotek, broszur, insertów

– inne prace zgodne z oczekiwaniami Klienta