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🏭 High-Volume Production Specialist

Precision Injection Molding Solutions

From rapid prototyping to mass production, we deliver complex, high-tolerance polymer components with advanced mold flow simulation, automated handling, and full material traceability.

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500K+
Parts/Month
±0.002"
Tolerance
300-2500T
Press Capacity
24/7
Unmanned Cells
Why Choose Our Injection Molding

Engineered for Scale, Precision & Speed

MetalCore's injection molding division combines decades of process engineering expertise with next-generation automation. Whether you need complex medical devices, automotive under-the-hood components, or consumer electronics housings, our team optimizes every stage of the production cycle.

We eliminate guesswork with advanced mold flow analysis, reduce cycle times with hot-runner technology, and guarantee consistency with SPC-driven quality controls. Every part ships with full material certification and traceability.

  • DFM Reviews within 48 hours of CAD submission
  • Class 100 Clean Room for medical & semiconductor parts
  • In-house mold building & maintenance (70% faster repairs)
  • Full secondary operations: overmolding, insert molding, assembly
  • USP Class VI, RoHS, REACH & FDA-compliant materials
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Core Capabilities

End-to-End Polymer Manufacturing

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Mold Design & Simulation

Advanced 3D mold flow analysis to predict warpage, sink marks, and filling patterns before steel is cut.

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Tooling & Mold Building

In-house CNC machining, EDM, and surface treatment for high-cavitation, long-life molds (1M+ shot life).

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Automated Production

Robotic part removal, in-mold labeling, vision inspection, and automated packaging for unmanned overnight runs.

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Quality & Certification

CMM inspection, First Article Inspection (FAI), PPAP documentation, and ongoing SPC monitoring.

Production Workflow

From CAD to Shipped Parts

1

Design & DFM

Geometry optimization & manufacturability review

2

Mold Flow Sim

Gating, cooling & filling analysis

3

Tooling Build

Precision machining & prototype runs

4

Production

High-volume runs with real-time monitoring

5

QC & Ship

FAI, certification & global logistics

Materials Database

Engineered Polymers & Composites

MaterialKey PropertiesCommon ApplicationsCertifications
ABSImpact resistance, gloss, ease of processingConsumer electronics, automotive trimUL 94 V-2
Polycarbonate (PC)High clarity, thermal stability, strengthMedical devices, optical lenses, housingsUSP Class VI FDA
Nylon 6/6 (PA66)Wear resistance, high temp, chemical resistantGears, connectors, under-hood auto partsRoHS REACH
PP / PolypropyleneLightweight, fatigue resistant, chemical inertPackaging, fluid systems, living hingesFood Grade
PEEK / PPSExtreme heat, high strength, biocompatibleAerospace, surgical implants, motorsISO 10993 AS9100
Machine Park

State-of-the-Art Presses & Automation

Haitian & Engel Injection Units

Electric & hybrid presses ranging from 300T to 2500T clamp force with ±0.1% injection repeatability.

Holzen & Husky Hot Runners

Precise temperature control systems for complex multi-cavity molds, reducing cycle time by up to 30%.

Yamaha & Fanuc Robotics

Delta pick-and-place, 6-axis articulating arms, and inline vision systems for 100% part inspection.

Altair Moldflow & Sigmasoft

Preventive simulation software to optimize cooling channels, gate placement, and material flow.

FAQ

Injection Molding Questions

What is the typical lead time for new mold tooling?
Standard production molds take 6-10 weeks depending on cavitation, complexity, and steel grade. Prototype molds can be delivered in 2-3 weeks using aluminum or 3D-printed conformal cooling.
Do you offer low-volume or bridge production?
Yes. We provide 3D-printed or soft-steel bridge tooling for 500-5,000 parts to validate designs and supply early market demand before hardening tooling.
Can you handle medical or aerospace-grade materials?
Absolutely. Our facility is ISO 13485 and AS9100 registered. We process PEEK, PPS, PC, and other certified polymers in controlled environments with full CoC and traceability.
What secondary operations do you provide?
We offer insert molding, overmolding (soft-touch grips), ultrasonic welding, laser marking, in-mold labeling, CNC trimming, and full assembly/packaging.
How do you ensure consistent part quality?
Every process runs with automated weight monitoring, SPC charts, and periodic CMM verification. We maintain PPAP Level 3 documentation and perform annual mold preventative maintenance.
Start Your Project

Ready to Scale Production?

Upload your CAD files or specifications and receive a detailed mold quote, DFM report, and timeline within 48 hours.