Engineered for Scale & Precision
\nMetalCore’s injection molding division combines advanced mold design, state-of-the-art processing equipment, and rigorous quality controls to deliver production parts that meet the most demanding specifications. From initial design-for-manufacturability (DFM) analysis to final assembly, we streamline your path from prototype to mass production.
Our facility houses 28+ injection molding machines ranging from 60-ton to 600-ton clamping force, equipped with automated robotic handling, vision inspection systems, and closed-loop process control to ensure consistency across millions of cycles.
Core Capabilities
Rapid Tooling
Aluminum and steel prototype tooling delivered in as little as 10-15 days for fast validation and early market entry.
Multi-Cavity & Family Molds
Optimized cavity designs to maximize throughput while maintaining part consistency and minimizing cycle times.
Overmolding & Insert Molding
Multi-material and hybrid part solutions that integrate soft-touch grips, living hinges, and embedded metal components.
Mold Flow Analysis
Advanced simulation to predict fill patterns, warpage, and cooling efficiency before steel is ever cut.
Our Molding Process
Every project follows our proven 5-stage methodology designed to eliminate bottlenecks and guarantee first-article success.
DFM Review & Optimization
Our engineers analyze your CAD models for manufacturability, suggesting wall thickness adjustments, gate locations, and draft angles to prevent defects.
Mold Design & Fabrication
Precision CNC and EDM machining of P20, H13, and S136 tool steels. Conformal cooling channels and hot runner systems integrated as needed.
Prototype & Validation
First article inspection (FAI), dimensional verification via CMM, and material property testing to meet IPC, FDA, or ISO standards.
High-Volume Production
Automated pick-and-place, in-line vision inspection, and real-time process monitoring (SPC) for uninterrupted output.
Assembly & Finishing
Secondary operations including ultrasonic welding, laser marking, adhesive bonding, and kitting/packaging ready for shipment.
Material Compatibility
We process over 200+ thermoplastic, elastomer, and composite materials. Below are our most frequently used grades:
| Material Family | Common Grades | Key Properties | Typical Applications |
|---|---|---|---|
| Polycarbonate (PC) | Lexan, Makrolon | High Impact Optical Clarity | Enclosures, medical devices, automotive lights |
| Nylon (PA6/PA66) | Stanyl, Zytel | Abrasion Res. Chemical Res. | Gears, connectors, under-hood components |
| ABS / PC-ABS | Cycolac, Terluran | Easy Process Surface Finish | Consumer electronics, housings, UI parts |
| PEEK / PPS | Victrex, Rynite | High Temp Biocompatible | Aerospace, surgical implants, semiconductor |
| TPU / TPE | Estane, Santoprene | Flexible Soft Touch | Grips, seals, overmolded components |
Quality Assurance & Standards
Certified Precision, Guaranteed Consistency
Our molding operations are backed by industry-leading certifications and rigorous process controls to ensure every part meets your specifications.
- ISO 9001:2015 & ISO 13485 (Medical Devices)
- IATF 16949 (Automotive Supply Chain)
- FDA 21 CFR Part 820 Compliant Clean Rooms
- Full material traceability & CoC/CoA documentation
- In-house CMM, optical scanning, & tensile testing lab
- Statistical Process Control (SPC) with real-time dashboards
Ready to Scale Your Production?
Submit your CAD files or part drawings for a free DFM review and competitive quote within 24 hours.
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