What materials are commonly used in rapid molding processes?

What Materials Are Commonly Used in Rapid Molding Processes?

Material Selection in Rapid Molding: Speed Meets Functionality

Rapid molding—encompassing techniques like rapid injection molding and soft tooling—is designed for producing functional prototypes or low-to-mid volume parts within days. Material choice is critical in balancing speed, cost, mechanical performance, and end-use requirements. Neway’s rapid molding services support a wide spectrum of thermoplastics and elastomers suitable for real-world testing and small-batch production.

Common Thermoplastics Used in Rapid Molding

1. ABS (Acrylonitrile Butadiene Styrene)

   • General-purpose thermoplastic with good impact resistance and machinability

   • Applications: Consumer electronics housings, automotive trim

   • ABS Info

2. PC (Polycarbonate)

   • High-impact strength and optical clarity; heat resistant up to 135°C

   • Applications: Lighting covers, lenses, impact-resistant enclosures

   • PC Info

3. PA (Nylon 6, Nylon 66)

   • High tensile strength, excellent wear resistance, and chemical stability

   • Applications: Gears, bushings, structural mechanical parts

   • Nylon PA Info

4. POM (Acetal/Delrin)

   • Low friction, excellent dimensional stability, and rigidity

   • Applications: Bearings, automotive fuel systems, fasteners

   • POM Info

5. PEEK (Polyether Ether Ketone)

   • High-performance polymer with thermal resistance up to 250°C and strong mechanical properties

   • Applications: Medical devices, aerospace parts, electrical insulators

   • PEEK Info

6. PP (Polypropylene)

   • Lightweight, chemical-resistant, and flexible

   • Applications: Living hinges, fluid containers, medical packaging

   • PP Info

7. TPE/TPU (Thermoplastic Elastomers)

   • Rubber-like flexibility, abrasion resistance, and excellent rebound

   • Applications: Seals, gaskets, wearable device components

   • TPU Info

8. PBT (Polybutylene Terephthalate)

   • Excellent electrical properties and dimensional stability

   • Applications: Connectors, automotive sensors, appliance parts

   • PBT Info

Specialty and Engineering Plastics

• Ultem (PEI): Flame-retardant and high heat resistance for aerospace and medical

• LCP (Liquid Crystal Polymer): Ideal for microelectronic and ultra-thin molded parts

• PSU, PPSU: Used where high steam resistance or sterilization cycles are needed

Factors Influencing Material Selection

1. Tooling Temperature Soft tooling (e.g., aluminum molds) limits the use of very high-temperature plastics like PEEK unless specially engineered.

2. Part Complexity Flexible materials like TPU are chosen for complex geometries and undercuts.

3. End-Use Requirements Materials must match thermal, mechanical, or regulatory standards based on application.

Integrated Services for Material Optimization

Neway enhances rapid molding outcomes through:

• Material Selection Consulting for balancing speed, cost, and performance

• Rapid Tooling with aluminum or hybrid steel molds

• Post-Molding Services like inspection, machining, and coating

With delivery in as fast as 7 days and ±0.05 mm accuracy, Neway’s rapid molding solutions support both prototype testing and functional end-use part production.