Thin Wall Injection Molding
Thin wall injection molding is an advanced plastic molding technique for producing parts with very thin wall sections, typically under 1 mm. It requires specialized injection molding machines, molds, and processing parameters to ensure the molten plastic flows evenly into the thin cavity and cools properly without defects like warpage
We help customers optimize and manufacture thin wall plastic products while employing advanced quality control measures to ensure plastic parts that meet specifications at a competitive cost.
  • Proven mold design solution
  • ISO 9001: 2015, IATF 16949 certified
  • Tolerance within ±0.0004 in (0.01mm)
  • 24/7 engineering support
  • Over 20 Years molding experience
Why Choose Attractive Plastics for Thin Wall Molding
Rich Thin Wall Molding Experience
We deeply understand the details of thin wall molding, from material selection, mold design and making, 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 thin wall injecton molding manufacturing. we will work closely with you to formulate a reliable molding plan.
Our proven mold design solutions ensure your thin-walled molded parts balance quality, efficiency and cost. Our advantages in automation provide customers with highly competitive cost advantages and access to a larger market.
Advantages of Thin Wall Injection Molding
Thin-wall injection molding can manufacture many lightweight plastic products. It not only reduces part weight and material consumption, but also reduces costs and production cycles. It is an ideal molding process for many fast-selling products.
Thinner walls can significantly reduce the weight of plastic components without compromising their structural integrity. This makes them ideal for industries with lightweight requirements, such as aerospace and automotive parts.
Improve Efficiency
Thin walls require shorter injection time and less cooling time, which greatly shortens the production cycle, improves production efficiency, and obtains a more competitive advantage.
Cost effective
Thin-wall injection molding is the ideal solution for producing large quantities of lightweight plastic parts. It has less material usage, shorter production cycle and extremely high production efficiency, which saves costs for manufacturers.
Quick Turnaround
Thin wall molding can effectively reduce fuel usage and shorten delivery times, which ensures quick turnaround.
Applications of Thin Wall Injection Molding
Thin wall molding has many advantages such as material saving, light weight, and cost reduction, and is widely used in many industries, such as food packaging, automotive, electronics, construction, home appliances, and aerospace, etc.
  • Medical – Medical disposables, syringes, medical tubing, connectors and device housings
  • Industrial – Storage containers
  • Consumer – Food packaging, Plastic cups and lids, containers
  • Automotive – Door panels, dashboard components, console parts and interior trim
  • Electrical – Computer components, mobile shell, Electrical connectors, switches, sockets and lighting components
Thin Wall Injection Molding Materials
At Attractive Plastics, in addition to providing a variety of conventional thin wall injection modlding materials, we also offer a variety of additive plastics to meet special requirements.
  • Regular Plastic Materials
  • Additives & Fibers Plastics
  • Mold Materials
Regular Plastic Materials
Thin walls will seriously affect the fluidity of materials during injection molding, so plastic materials for thin-wall molding must have excellent fluidity. This is the basic principle when selecting materials for thin-walled plastic parts. Especially when molding ultra-thin-walled plastic parts, an increase or decrease in wall thickness of 0.01mm has a decisive effect on the success of the part.
The common thin wall molding plastic materials recommended: PP, ABS, PMMA, Nylon, PE, PBT, SAN, PS, LCP
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Additives & Fibers Plastics
Additives will affect the fluidity of the material, so most thin-walled plastic parts don't add any additives and fibers. However, some industrial thin-walled plastic parts are also added to improve their mechanical properties.
Examples of common additives include:
  • UV absorbers
  • Flame retardants
  • Plasticizers
  • Carbon fibers
  • Antistatic additives
  • Glass fibers
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Mold Materials
During the injection molding of thin-walled plastic parts, the mold must withstand high temperature and pressure, so the thin-walled molding mold materials must meet the characteristics of high strength, high hardness, high thermal conductivity, high corrosion resistance, and easy processing.
Mold Steel: P20, 718, 718H, 2738H, H13, S7, NAK80, S136
Stainless Steel: 420, NAK80, S136, 301, 303, 304, 316
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Thin Wall Injection Molding Design Tips/Considerations
Typically, "thin wall" is considered plastic parts with a wall thickness of less than 1 mm. The process requirements for thin-wall injection molding are very different from those for standard plastic injection molding. It requires higher pressures and speeds, shorter cooling times, and well-designed ejections and gates.
Design tips/considerations
Plastic material
When selecting raw materials, fluidity, toughness, etc. should be considered, but try to choose plastics that will not accelerate mold wear during high-speed injection.
Mold material
The impact of high pressure and high speed on the mold material is huge. Improper material selection, incorrect placement of cooling and heating elements, and other design flaws may cause the mold to crack.
Uniform wall thickness
Make sure the part has a uniform wall thickness whenever possible. This allows for even cooling and helps prevent warping, sink marks, flow lines and short shots. For best results, keep wall thickness to at least 1mm or greater.
Stiffeners are designed to be 60% of wall thickness or less. Improperly designed ribs may cause warping, sink marks, trapped air, breakage, or failure to release from the mold. For deep ribs, please increase the ejector pin and draft angle.
Mold temperature
Mold temperature can increase plastic flow and plays a key role in thin-wall molding. A warmer mold allows the injected plastic to flow more easily, resulting in better surface quality.
Well-design gate
Gate size should be larger than the part walls to help minimize gate wear and material shear. This will also help reduce gate freezing.
Mold cooling
Instead of lowering the coolant temperature, try to increase the coolant flow through the cavity of the mold core to keep the surface temperature of the mold as consistent as possible to increase the probability of success.
Draft angle
The shrinkage of thin-walled plastic parts is small, so it is necessary to increase the draft angle of ribs, edges and bosses for smooth demoulding.
Good polishing can reduce the flow resistance of the plastic and speed up the flow. For thin ribs, poor polishing will seriously affect stripping.
Superior Custom Thin Wall Molding Manufacturer
As a leading manufacturer of thin wall molding. Our experienced team utilizes advanced technologies and rigorous quality controls to ensure that every detail is meticulously crafted. We understand the unique challenges associated with thin wall molding, and we have mastered the techniques required to produce parts that are both functional and aesthetically pleasing.
Our commitment to innovation and excellence has allowed us to expand our thin wall molding capabilities beyond traditional applications. We specialize in creating complex designs with intricate features, making us a trusted partner for even the most demanding manufacturing requirements. Whether you need thin wall parts for consumer products, medical devices, or industrial components, we have the expertise and technology to deliver solutions that are tailored to your specific needs.
Gallery of Thin Wall Injection Molding Products
Dive into Attractive Plastics' extensive gallery that showcases some of our completed thin wall molding parts and take confidence that we can create your thin wall injection molding 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.
Their expertise in thin-wall molding enabled production of our new medical device housing with walls less than 0.5mm. Careful gate placement and packing pressure optimization resulted in strong yet ultra-thin walled parts meeting all dimensional requirements.
David Moon
Vice President
Through in-depth mold flow simulations, they implemented conformal cooling channels to evenly extract heat from our complex thin-walled connector housing. Intricate geometry typically causing warping is now defect-free at high output.
Carl Harris
Pruchasing Manager
Their skilled technicians performed preventative maintenance and calibration checks, ensuring tooling longevity unmarried by our continuous 24/7 production. Reliability supports our just-in-time delivery model.
Tony Jones
We worked closely with their engineers to validate a new venting strategy for injection molding our complex 1.2mm medical device casing. It eliminated air traps and facilitates stringent leak testing requirements.
Ben Holder
Mold flow simulations optimized gate locations to avoid cosmetic flaws at minimum material waste. Reduction lowered per-part costs 15% from earlier quote without compromising quality standards.
Anne Zaremba
Our Thin Wall Molding Molding Service for Various Industries
Our thin wall injection molding process is suitable for solve the various demands of industries, including the automotive, medical, electronic & electrical and consumer goods fields etc.
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Thin Wall Injection Molding Molding FAQs

What is thin wall injection molding?

Thin wall injection molding is a specialized injection molding process for producing plastic parts with wall thicknesses below 1 mm. It requires high-performance injection molding machines, well-designed molds, low viscosity plastics, and tight process control to fill thin sections completely and minimize defects. Key applications include thin wall packaging, electronic housings, and lightweight consumer products.

What’s thin wall plastic products/parts?

  • We usually plastic parts with a wall thickness of less than 1 mm are called thin wall parts, and the injection molding process for making such thin wall plastic parts is called thin wall injection molding.
  • In injection molding, when L/T is greater than 150, it is called thin wall, and “L” refers to the longest distance from the melt into the mold cavity to the full filling.”T” is the corresponding average wall thickness.

What are thin wall molding considerations?

These are some considerations of thin wall moling:

  • Specialized injection molding machines with high injection pressures and speeds are required to fill thin wall parts.
  • Mold design is critical to ensure proper and balanced filling of the thin wall sections. Flow leaders and gates need to be optimized.
  • Materials must have low viscosities to flow easily into thin cavities and minimize defects like short shots. Common materials are PS, PP, PE, PVC.
  • Processing parameters including melt temperature, injection speed, packing pressure, and cooling time need tight control to ensure adequate filling without warpage.
  • Demolding can be challenging for thin parts and requires angled drafts and proper ejection systems.

What are the challenges of thin wall injection molding?

Producing high quality, dimensionally accurate thin wall parts via injection molding requires careful attention to process control, mold design, material selection, and simulation analysis.

Here are some key challenges associated with thin wall injection molding:

  • Fill and packing – Thin walls make it difficult to fill the mold cavity completely and obtain proper fusion across the cross-section. This can lead to short shots, weak points, and cosmetic defects. Precise process control is required.
  • Dimensional tolerance – Thin walls are prone to variation and distortion. Maintaining tight dimensional tolerances across thin sections is challenging.
  • Warpage – Residual stresses tend to warp and distort thin parts upon ejection. Parts may require additional cooling time in the mold to enhance dimensional stability.
  • Demolding – Thin parts can deform or break when ejected from the mold due to inadequate stiffness. Proper draft angles, ejector design and control of shrinkage stresses are needed.
  • Surface defects – Any minor variation in melt flow, temperature or mold surface can result in visible flow lines, jetting, sink marks and other defects on thin walls. Highly polished mold surfaces are essential.
  • Resin selection – The resin must have low viscosity and high strength at thin wall thickness.Low viscosity can increase material fluidity, accelerate filling, and increase the probability of successful molding.
  • Mold strength – High injection pressures are needed to fill thin walls, exerting high clamp forces. The mold must have adequate mechanical strength.

What are the benefits of thin wall injection molding?

Thin-wall molding has significant advantages in reducing weight, saving materials, improving strength, saving costs, optimizing design, and facilitating integrated design and assembly. However, in practical applications, it is also necessary to select appropriate molding processes and materials based on specific product requirements and process conditions to fully exploit their advantages and overcome potential challenges. Take a look at its main advantages below:

  • Lightweight: Thin-wall molding can reduce the weight of the product, making it lighter, more portable, and easier to use.
  • Material saving: Using less material to manufacture the product, reducing production costs.
  • High efficiency: Thin-wall molding can typically achieve rapid production, improving production efficiency.
  • Increased design flexibility: It is possible to manufacture more complex shapes and structures, providing more possibilities for product design.
  • Low cost: Less material saves costs, shorter cycle times, and faster speeds save injection molding costs, all of which are ways to save costs.
  • Good heat dissipation: The thin-wall structure facilitates heat dissipation, which is important for some heat-generating equipment.

What industries are using thin wall injection molding?

  • Food packaging jar
  • Automotive plastic parts
  • Medical equipment
  • Plastic containers
  • Aerospace
  • Consumer goods packaging box
  • Electronic housing and protection
  • Mobile & computer shell
Thin Wall Injection Molding Resources
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