Injection molding is a manufacturing process used to create a variety of plastic parts and products. There are many factors to consider when planning an injection molding project, including who will provide the services. The first thing you should determine is quantity, as it helps narrow down which companies have the necessary resources to accommodate your project.
Yields can be divided into three categories: small yields, medium yields and large yields. The following article highlights the differences between low and high capacity.
Table of Contents
- Low-volume plastic injection molding
- High-volume plastic injection molding
- What are the advantages and disadvantages of low-volume vs. high-volume plastic injection molding?
- What is low-volume, high-volume manufacturing?
- What to do with products with large quantities but few varieties?
- Why is mass production preferred for large quantities and small varieties?
- Low-volume production vs. large batch production
- Which injection molding process is best for your situation?
- Partner with HingTung for your high-volume injection molding needs
Low-volume plastic injection molding
Low-volume injection molding operations typically involve less than 10,000 parts, depending on the method used. The tools used are made of aluminum rather than the hardened steel used in mass-produced tools.
Compared with large-volume injection molding, small-volume injection molding has the following advantages:
Reduce mold costs and shorten turnaround time. Aluminum molds are easier and cheaper to make than steel molds.
Greater design flexibility. Because low-volume molds can be manufactured faster and at lower costs, injection molding companies can more easily create new molds to accommodate changes in component designs.
Easier access to market. Low-volume injection molding offers lower initial costs and shorter turnaround times, making it easier for new or smaller companies on a tight budget to produce their parts and products.
Low-volume injection molding is best suited for:
Prototyping. Low-volume injection molding is fast, low-cost, and ideal for creating prototypes for testing form, fit, and function.
Market testing and pilot production. Low-volume injection molding is ideal for manufacturing products for market testing. It can also be used to manufacture products when setting up a high-volume production business.
Low-volume production runs. Low-volume injection molding is ideal for injection molding projects that do not require the production of hundreds of thousands or millions of products.
High-volume plastic injection molding
High-volume injection molding operations typically involve hundreds of thousands to millions of pieces. The tools used are made of hardened steel rather than the aluminum used in low-volume production tools.
Compared with Low-volume injection molding, large batch injection molding has the following advantages:
Larger capacity and faster speeds. High-volume injection molding operations can produce hundreds of thousands or millions of parts at a time.
Lower unit cost. While high-volume injection molds have higher initial costs than low-volume injection molds, the durability of hardened steel molds allows more parts to be made before replacement is needed. Therefore, depending on the number of components produced, the overall unit cost may be much lower.
More suitable for automation. High-volume injection molding processes are well suited to automation, which can further increase throughput and reduce unit costs.
High-volume injection molding is best suited for mass production. Companies frequently use it to produce parts and products in quantities ranging from 750,000 to over 1,000,000 units.
What are the advantages and disadvantages of low-volume vs. high-volume plastic injection molding?
| Features/types | Low-volume plastic injection molding | High-volume plastic injection molding |
|---|---|---|
| Production quantity | Less | A lot |
| Cost | Relatively high, unit cost is large | Relatively low, unit cost is small |
| Tool cost | Relatively low, suitable for simple molds | Relatively high, suitable for complex molds |
| Production cycle | Relatively short, suitable for small-scale needs | Relatively long, suitable for mass production |
| Design flexibility | Higher, can be adjusted according to needs | Lower, usually requiring a more stable design |
| Equipment utilization | Relatively low and short production time | Relatively high, long production time |
| Inventory management | Relatively simple and avoids large inventories | Need for an effective inventory management system |
| Risk | Low risk, suitable for trial production of new products | Higher risk, suitable for stable product production |
| Flexibility | Adapt to market changes and have high flexibility | Production is relatively fixed and flexibility is low |
| Repeated manufacturing | Relatively easy to modify and update | Modification is difficult and usually requires re-manufacturing |
What is low-volume, high-volume manufacturing?
Low-volume high-volume manufacturing, also known as high-volume low-volume (HMLV), is the process of producing many different products in Low-volumees. This is a common technique for producing unique, complex products with specific quality requirements. HMLV production requires frequent job modifications, material changes, and equipment adjustments.
Operators working in this environment face a lot of variability when it comes to high-volume low-volume production lines and wide-ranging product demands. This often results in inconsistencies and errors in the arrangement of work and materials.
The choice between high-volume and low-volume manufacturing processes depends primarily on the market demand for the product. In contrast to common approaches to high-volume and low-volume production, market testing is often more feasible in low-volume, high-variety production. If you are bringing a new product to market, then high-variety, low-volume production may be best for you.
high-volume low-volume manufacturing enables you to conduct better market testing. This is a more convenient way to introduce and evaluate new products without the need for high-volume production.
By doing this, you can minimize your financial risk and adjust your product as your needs change. Although it is a more complex manufacturing process, high-variety, low-volume manufacturing provides you with adaptability that can give you an advantage over your competitors.
What to do with products with large quantities but few varieties?
For high-volume but low-variety products, you can use several different types of manufacturing processes. The first is low-volume injection molding, the process of injecting molten plastic into a mold to create a product.
This way you can produce large quantities of products quickly and efficiently. However, one drawback to this approach is that the setup cost can be quite expensive. If you have a smaller budget, this may not be the best option for you. You may initially focus on low-volume manufacturing and then shift your strategy toward high-volume vs. low-volume manufacturing based on market demand.
Another option for high-volume but small-variety products is small-batch manufacturing. In this process, your product is manufactured using CNC machines (computer-controlled cutting tools). This method is cheaper than low-volume injection molding, but it also has some disadvantages.
Another option is mass production, also known as high-volume manufacturing. This is the most common manufacturing method and has many advantages. One of the advantages of mass production is that it is very fast. This method is also very efficient and can produce large quantities of products quickly and cheaply.
The downside to mass production is that it can be very impersonal. This method is also less suitable for products that require a lot of customization or detail.
Why is mass production preferred for large quantities and small varieties?
Large-scale production is often preferred over HMLV for large batches and small varieties because it allows manufacturers to reduce costs while still ensuring quality. This type of production is more efficient and less labor intensive, often resulting in significant cost savings.
Different approaches are required when planning logistics and supply chains for high-volume and low-volume manufacturing. By producing in Low-volumees, you don't have to worry about excess inventory. However, if you need to meet larger demands, you should opt for high-volume production.
That said, businesses looking to produce products in smaller batches may find that low-volume production is a better option. This is because low-volume production is generally more flexible and can accommodate a wider range of product designs. Low-volume contract manufacturing also gives you greater control over the design and customization of your product.
Low-volume production vs. large batch production
So, which one is right for your project? Should you use high-volume or low-volume production? It depends on your needs. If you need a large number of parts quickly and can afford the unit cost, high-volume manufacturing may be the best option.
However, if you need smaller quantities of parts and have some flexibility in delivery times, low-volume manufacturing may be a better solution.
Still not sure which one is right for you? HingTung has over 12 years of experience in low-volume and high-volume manufacturing. We can help you determine the best production method for your project based on your individual needs. Contact us today to get started.
Work with a professional manufacturer and get a quote today!
Which injection molding process is best for your situation?
Low-volume and high-volume injection molding each have advantages and disadvantages. This choice requires consideration of the following factors:
Production requirements: It is not reasonable to perform high-volume injection molding until production requirements are below 75,000 units. This means that low-volume injection molding is the best option for smaller production capacities.
Design needs: If the design is unique, low-volume injection molding is the obvious choice because it allows for economical experimentation with tooling.
Production costs: When unit production costs are rising, companies should focus on prototyping and automation. In this case, high-volume injection molding is the only option available as it significantly reduces production costs.
Setup Budget: When the setup budget is limited, it is inevitable to start with Low-volume injection molding, as the high-volume process will require a large initial investment. Steel tools participating in high-volume forming require longer production times and higher material costs.
Partner with HingTung for your high-volume injection molding needs
Before selecting a plastic injection molding supplier for your project, verify that they have the resources to meet your volume requirements. For high-volume manufacturing projects, HingTung Group is the ideal partner. To learn more about our injection molding capabilities, contact us today. To discuss your project with one of our team members, please request a quote.