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Precision Plastic Injection Molding Services
GC Indus operates 5000 ㎡ of dedicated molding facilities featuring:
✔ Class 8 cleanroom molding for medical applications
✔ 900-ton to 3,000-ton press capacity
✔ ±0.02mm tolerances for critical components
✔ Material science laboratory for formulation testing
✔ Full vertical integration from tooling to assembly
Our IATF 16949 and ISO 13485 certified processes ensure manufacturing excellence across all molding technologies.
1. Injection Molding Services
- Micro-molding: Parts under 1g with LSR/TPE
- Overmolding: Multi-material components
- Gas-assisted: Hollow structural parts
- Insert molding: Metal/plastic hybrids
Equipment: 15+ presses (25-3,000 ton)
Cycle Times: 15-90 seconds
2. Die Casting Solutions
- Cold chamber: Aluminum/Magnesium
- Hot chamber: Zinc alloys
- Vacuum-assisted: Reduced porosity
- Squeeze casting: Enhanced mechanicals
Tolerances: ±0.05mm typical
3. Precision Casting
- Investment casting: 0.5mm wall thickness
- Sand casting: Up to 500kg parts
- Ceramic mold: Aerospace components
- Lost foam: Complex geometries
Surface Finish: 1.6-3.2μm Ra
4. Compression Molding
- BMC/SMC: Structural composites
- Rubber molding: 30-90 Shore A
- GMT: Automotive panels
- Toric molding: Optical components
Pressure Range: 50-300 bar
5. Rapid Tooling
- Aluminum molds: 2-3 week lead time
- 3D printed tooling: <7 day prototypes
- Bridge tooling: 500-50,000 shots
- Mold modifications: Design iterations
Technical Specifications by Process
| Process | Tolerance | Max Part Size | Min Wall | Annual Capacity |
|---|---|---|---|---|
| Injection | ±0.02mm | 1500x800mm | 0.2mm | 50M+ parts |
| Die Cast | ±0.05mm | 600x400mm | 1.0mm | 2,500 tons |
| Precision Cast | ±0.1mm | 1000mm dia | 0.5mm | 1,000 patterns |
| Compression | ±0.15mm | 2000x1000mm | 1.5mm | 500K parts |
| Rapid Tool | ±0.1mm | 500x500mm | 0.8mm | 200 tools |
Medical Device Manufacturing
- Injection: Surgical instrument handles
- Die Cast: Imaging equipment housings
- Investment Cast: Orthopedic implants
Automotive Systems
- Compression: EV battery enclosures
- Die Cast: Transmission cases
- Injection: Interior trim components
Aerospace Components
- Investment Cast: Turbine blades
- Compression: Radome covers
- Die Cast: Flight control systems
Consumer Electronics
- Micro-molding: Connector housings
- Die Cast: Heat sinks
- Injection: Wearable device frames
Material Science Expertise
Engineered Material Solutions:
▸ Medical-grade PEEK/PEKK
▸ EMI-shielding compounds
▸ Flame-retardant polymers
▸ High-thermal conductivity alloys
▸ FDA-compliant elastomers
Advanced Material Testing:
• Rheological analysis
• DSC/TGA thermal profiling
• Mechanical property validation
• Chemical resistance testing
Quality Management System
- Tooling Qualification
- Moldflow analysis
- Steel certification
- Cavity pressure monitoring
- Process Validation
- IQ/OQ/PQ protocols
- Statistical process control
- CpK >1.67 standards
- Inspection Methodology
- CT scanning for internal features
- CMM inspection ±2μm
- Spectrochemical analysis
- Certifications
- ISO 13485:2016 Medical
- IATF 16949 Automotive
- NADCAP Aerospace
Technical Advantages
Innovative Molding Technologies:
• Conformal cooling for 30% faster cycles
• In-mold sensors for real-time QC
• Multi-shot rotary platens
• Automated degating systems
Engineering Support Services:
- DFM reports within 24 hours
- Moldflow simulation
- Gate optimization studies
- Cost-reduction analysis
Project Workflow
- Design Consultation
- Material selection
- Tolerance analysis
- Moldability assessment
- Tooling Development
- Precision machining
- Surface treatments
- Trial runs
- Production Validation
- First article inspection
- Process capability studies
- PPAP documentation
- Volume Manufacturing
- Automated production
- Lot traceability
- Just-in-time delivery
Why Partner With GC Indus?
✔ 13+ Years of molding expertise
✔ 1,200+ active tooling designs
✔ 15% typical cost savings vs. industry
✔ 30% faster time-to-market
✔ 0.25% defect rate
Start Your Molding Project
Submit your requirements for a comprehensive technical proposal within 48 hours.
Molding Services FAQ
Q: What’s your tooling lead time for production molds?
A: 8-12 weeks for hardened steel molds, 2-3 weeks for aluminum prototype tools.
Q: Do you handle FDA-approved materials for medical devices?
A: Yes, we maintain FDA Master Files for common medical polymers and validate all material certifications.
Q: Can you produce multi-cavity tools for high volume?
A: Our 128-cavity micro-molding tools regularly produce components at >1M parts/month volumes.
Q: What secondary operations do you offer?
A: Full-service options including laser marking, ultrasonic welding, ESD coating, and sterile packaging.
