High Temperature Injection Molding
High temperature injection molding is an injection molding process that uses high heat-resistant/performance plastic materials, allowing molding at temperatures above 550°F (288°C). This process enables molding of high performance thermoplastics like PEEK, PFA, PEI, PPS, LCP for parts requiring high heat resistance, dimensional stability, and mechanical strength.
High temperature molding presents huge challenges, which requires precise control and careful processing of details from product design to mold production, mechinel size selection, molding temperature, mold temperature, etc.
  • Tolerance within +/- 0.0004 in (0.01mm)
  • Over 50+ high temperature materials knowledge
  • Mold making and prototyping
  • ISO 9001:2015, IATF 16949:2015 certificated
  • 24/7 engineering support
Why Choose Attractive Plastics for High Temperature Molding
Rich High Temperature Molding Experience
We deeply understand every detail of high temperature molding, from material selection, molding temperature, mold temperature, process control to machine selection, etc. Strictly grasping every detail is the key to success.
Quality Assurance
We rely on advanced measuring equipment, as well as a skilled team of quality engineers, technicians and inspectors. We will take the careful measurements necessary for each project to ensure that you receive the highest quality components.
Strong Engineering Team
Our engineering team with over 20 years of experience provides strong professional knowledge and technical support in precision insert molding tooling manufacturing. we will work closely with you to formulate a reliable mold design and machining plan.
We offer design for manufacturability analysis to ensure that your insert molding parts balance quality, efficiency and cost. Our advantages of automation and upfront mold design translate into more competitive pricing when running in high volumes, which also enables our customers to reach a larger market.
Applications of High Temperature Molding
High temperature plastics have many advantages such as temperature resistance, moisture resistance, dimensional stability, flame retardancy, and UV resistance, making them widely used in many industries. For example, it is used in automotive parts to replace metal parts. PEI burns with very little smoke, making it commonly used in aircraft parts. It is used in PPSU medical device parts that need to be sterilized, and it is used in outdoor PPO power accessories, etc.
  • Tolerance within +/- 0.0004 in (0.01mm)
  • Over 50+ high temperature materials knowledge
  • Mold making and prototyping
  • ISO 9001:2015, IATF 16949:2015 certificated
  • 24/7 engineering support
Advantages of High Temperature Injection Molding
High-temperature plastics have many advantages that other conventional plastics cannot provide. They are ideal materials for improving part performance, lightweighting, and reducing costs. This enables high temperature plastic parts with superior mechanical, thermal, and chemical resistance properties.
Strong Mechanical Properties
The characteristics of high-temperature materials such as high strength and high toughness make plastic parts formed at high temperatures have strong mechanical properties.
High Dimension Stability
High temperature plastic parts are more resistant to warping and shrinkage than parts molded at lower temperatures, resulting in high dimensional stability.
Reduced Cost
High temperature materials are often used to replace metal parts. Although the molding cost is higher than standard injection molding, its durability compared to metal parts makes its cost much lower than other materials.
Excellent Chemical Resistance
High temperature materials with high chemical resistance make molded plastic products excellent in resisting chemicals.
High Temperature Injection Molding Materials
At Attractive Plastics, in addition to providing a variety of conventional high performance plastic injection molding materials, we also offer a variety of additive plastics to meet special requirements.
  • High Temperature Plastic Materials
  • Additives & Fibers Plastics
  • Mold Materials
High Temperature Plastic Materials
We provide a variety of high temperature plastic materials with different properties to meet applications in different environments.
Common high performance plastic materials include: PEEK, PTFE(PFA), PPS, LCP, PPA, PEI, PES, PPSU, PPO, PAI.
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Additives & Fibers Plastics
If standard high performance engineering plastic materials can't meet the requirements of customized high temperature molding parts, additives and fibers can be added to improve mechanical properties or other requirements to help your high temperature injection molded parts successfully go on the market.
Examples of common additives include:
  • UV absorbers
  • Flame retardants
  • Plasticizers
  • Carbon fibers
  • Antistatic additives
  • Glass fibers
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High Temperature Molding Mold Materials
Most high temperature plastics require high mold temperatures when molding. Repeated high temperature and cooling for a long time will generate a large amount of internal stress, causing cracking of the cavity core and surface damage, etc. This is a great challenge to mold steel.
Some plastics resion( such PVC, PFA) will produce corrosive gases during molding. For this type of material, super corrosion-resistant mold steel must be used (recommended S136, M340), or the mold surface should be chromium-plated to achieve anti-corrosion purposes.
Recommendation Types: H13, S136, S136H, 420, 430, M340
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High Temperature Injection Molding Design Tips/Considerations
High temperature molding has significant challenges, which may be due to equipment, material treatment and mold design, manufacturing, process, etc. Therefore, each step in the molding process requires special consideration and careful handling.
Design tips/considerations
Mold design
The mold needs to be designed for extremely high heat-resistant temperatures and clearances, and necessary heat shield devices are required.
Select the right mold steel
Mold materials must be able to withstand high temperatures for long periods of time and be corrosion-resistant. Some materials (PFA, PVDF) will release corrosive gases during molding. The mold cavity can be electroplated to increase durability.
Plastic material
Plastic raw materials are the first factor to consider for any micro-molded plastic parts and are also the key to the successful launch of the product.
Heating/cooling channel
Mold heat transfer channels are crucial to molding. The mold design should be analyzed and tested to make the heat on all surfaces of the mold as uniform as possible.
Mold temperature
The mold temperature required for molding each high-temperature plastics is different, but the mold temperature plays a key role in molding.
Mold Maintenance
High temperature molds are subject to high temperatures for a long time, causing great wear and tear on the molds. Regular mold maintenance is particularly important.
The correct size of the injection machine must be selected, and ceramic heating bands and special alloy screws must be used. An optimally sized machine minimizes the time spent in production while achieving optimal injection speed and pressure.
Molding technology
It is generally recommended that the raw materials in the screw should not stay for more than 10 minutes to avoid resin degradation caused by high temperatures for a long time.
The right molding temperature
Maintaining consistent temperatures is important when processing high temperature plastics. The heating tapes, hot runners and thermocouples used must be strictly controlled to ensure temperature stability in the barrel and mold.
Gallery of High Temperature Injection Molding Parts
Dive into Attractive Plastics' extensive gallery that showcases some of our completed high temperature molding parts and take confidence that we can create your high performance plastic project according to your strict specifications.
Reviews from Our Customers
A customer’s words have a more substantial persuasion than a company’s claims. We have served hundreds of satisfied customers and here are some reviews they give us.
From initial design suggestions, structural design, to mold making and mass production, they always carefully inspect every production process. This is also the reason why there are few complaints about the products they produce. Although the price is relatively high, it is within our acceptable range.
David Moon
Vice President
We were impressed by prototype parts molded from an exotic PAI material at 400°F. Extensive heat/strength testing proved the material's viability for our industrial controls application. Their capabilities facilitate material trials that quickly validate technical feasibility.
Carl Harris
Pruchasing Manager
Their expertise in high-temperature resin selection and processing enabled prototyping of our new thermoplastic connector housings. Parts withstood the necessary 105°C reflow with no deformation or discoloration, meeting our stringent thermal specifications.
Tony Jones
We are very satisfied with their ability to achieve full inspection of PPS injection molded parts with tight tolerance control. Several of our other suppliers can't meet the full inspection requirements if the tolerance is as high as ±0.01mm. They can do what others can't, and that's the fundamental reason why we choose them.
Ben Holder
Recently, there was a temporary increase in large orders. They worked with us to optimize the production process and allocate more production resources, successfully increasing the output by 40% without reducing quality. Their excellent collaborative spirit has won us more orders and new customers.
Anne Zaremba
Our High Temperature Injection Molding Service for Various Industries
Our custom high temperature injection molding process is suitable for solve the various demands of industries, including the automotive, medical, electronic & electrical and consumer goods fields.
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High Temperature Injection Molding FAQs

What are the common high temperature plastics?

Common types of high temperature plastics include polyimides (PI), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), liquid crystal polymers (LCP), Polyethersulfone (PES), Polyphenylsulfone (PPSU), Polyether Imide (PEI), Polysulfone (PSU), PolyEtherKetone-EtherKetoneKetone (PEKEKK), Polyetherketone (PEK), Polytetrafluoroethylene(PTFE), Perfluoroalkoxy Alkanes (PFA), Polyvinylidene Fluoride(PVDF), polysulfones.Key application areas are in aerospace, automotive, oil & gas, electronics and medical sectors.

What is high temperature injection molding?

High Temperature Injection Molding is an injection molding technology characterized by the injection filling and cooling process when the mold temperature is usually higher than 150°C and the molding temperature is usually higher than 300°C.

Different from conventional injection molding, high-temperature injection molding uses high-temperature molds to reduce the viscosity of the molten plastic and enhance the fluidity of the material in the mold cavity. It can fill the mold cavity more fully and evenly, reduce flow lines and internal stress, and improve the appearance of molded parts. . These advantages make it particularly suitable for materials such as engineering plastics that are difficult to mold at conventional temperatures. For example, PEEK, PPS, PFA, PEI, PES, etc.

However, high-temperature injection molding also places higher requirements on mold materials and cooling systems. Care must be taken to prevent long-term high temperature damage to the mold.

What are high temperature plastics?

High temperature plastics also called high-performance plastics, refer to a class of high performance thermoplastic polymers that can withstand and operate at elevated temperatures, typically in the range of 150°C to over 260°C. Some key characteristics of high temperature plastics:

  • High heat resistance and thermal stability at continuous-use temperatures above 150°C without significant thermal degradation or dimensional changes. This high heat distortion temperature allows them to replace metals in many applications.
  • Good mechanical properties such as strength, stiffness, creep resistance and toughness at both room and elevated temperatures. This allows them to maintain mechanical performance when exposed to heat.
  • High chemical resistance against acids, bases, fuels, oils and solvents. This provides durability in harsh chemical environments.
  • Flame retardance and self-extinguishing properties for safety in high heat applications.

What are the challenges of high temperature injection molding?

Here are some of the main challenges associated with high temperature injection molding:

  • Mold materials – The mold must withstand prolonged exposure to high temperatures without losing dimensional stability or wearing prematurely. This requires mold materials like beryllium-copper alloys or specialized tool steels.
  • Thermal expansion – The significant expansion and contraction of mold components with temperature cycling can lead to issues with precision, part quality, and mold life. Precise allowance must be made for thermal expansion.
  • Cooling system – An efficient cooling system is critical to bring down cycle times. This is challenging due to the hot mold surfaces. Conformal cooling channels close to the mold surfaces are often required.
  • Process control – Tight control over temperatures, pressures, timing, and velocities is crucial to achieve a balanced fill and optimum part quality. This requires precise process monitoring and control.
  • Part ejection – Hot parts tend to stick in the mold or deform during ejection. The right ejection force, timing, and temperature control is important.
  • Resin drying – Many high temperature polymers are hygroscopic. Adequate resin drying is essential to avoid splay and inconsistent properties.
  • Warpage and stresses – Residual stresses due to uneven cooling and shrinkage can induce significant warpage in parts. This may require modifications in part and mold design.
  • Cost – The mold materials, cooling requirements, and process control systems required make high temperature injection molding an expensive process.

What are the key factors for successful high temperature injection molding?

As a high temperature molding company with over 15 years of experience, we have extensive experience in this type of high performance plastics molding. Here are some of the key points we summarized. Careful selection of mold materials, mold deign, mold making, process optimization, tolerance control and mold flow analysis are key enablers for high temperature injection molding.

Here are some key factors for successful high temperature injection molding:

  • Mold materials – Use hardened tool steels or beryllium-copper alloys to withstand prolonged exposure to temperatures above 150°C.
  • Mold cooling system – Effective conformal cooling channels close to the mold surfaces are essential for rapid cycling.
  • Temperature controls – Precise monitoring and control of nozzle, barrel, mold temperatures to maintain process consistency.
  • Materialdrying – Many high temp polymers are hygroscopic. Moisture content must be kept very low through proper drying.
  • Dimensional tolerance – Account for and minimize thermal expansion effects to maintain tight tolerances.
  • Part and mold design – Optimize wall thickness and geometry to ensure adequate stiffness and avoid warpage.
  • Demolding – Controlled ejection force and timing required to avoid part distortion while hot.
  • Process monitoring – Critical process parameters need real-time monitoring to identify any deviations.

What about the cost of high temperature molding?

While high-temperature molding can achieve higher quality parts, the costs involved tend to be higher than conventional injection molding, both in terms of material costs and mold and injection molding costs. But compared with the cost of other materials, it still has advantages. High-temperature plastic parts have a long service life, are resistant to high temperatures and corrosion, are lightweight and durable. Therefore, in the long run, the cost is lower than products made of iron, aluminum and other materials.

High Temperature Injection Molding Resources
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