How to Reduce Costs in Injection Molding: 7 Proven Strategies for 2025
If we think of most efficient mass production process of plastic parts, injection molding comes on top of mind. But we can admit that there is a significant investment involved in the injection molding manufacturing process. Whether it is an automotive component or medical device part, slightest error or lack of attention can lead to significant capital loss. Besides, there is rise in price of raw material and cost of energy. Therefore, it is imperative to optimize cost to stay afloat in the global competition.
But there’s no need to make do major overhauling of your process or compromise on quality and quantity of your products. We live in a smart world era where no strategic changes are out of scope. There are technologies, methods and optimization techniques which can surely reduce the cost of injection molding. In this comprehensive blog, we will explain 7 proven strategies that will help you to reduce the stress on your finances and boost profitability in your injection molding projects in the year 2025:
1. Optimize Material Selection
In injection molding process, around 50-70% of total expenses goes in material. By reconsidering the material procuring process, you can yield massive savings. Here are some methods:
- Recycled or Bio-Based Resins: Instead of virgin plastics, choose recycled materials like PET or PLA which are cheaper option, give similar performance and align with sustainability goals.
- Avoid Over-Engineering: Check if you are performing excessive engineering on the resin. If yes, downgrade to a more cost-effective resin if the mechanical demand allows it to be.
- Reliable Vendors: Maintain long term relationship with vendors so you get authentic material and discounts on bulk buying.
Pro Tip: A material selection software like UL Prospector compares resin properties and prices.
2. Simplify Part Design with DFM (Design for Manufacturability)
Design for Manufacturability (DFM) is a reliable cost saver as it involves tactics to simply the design and make them easier and cheaper to manufacture. By implementing these tactics, you can slash expenses by 30%.
- Reduce Wall Thickness: Aim for uniform walls (1.5-3mm for most plastics) instead of thick walls that waste material, slows down cooling, and create sink marks.
- Eliminate Undercuts: Modify the parts with straight pulls which simply tooling because undercuts require complex side-action molds.
- Standardization: Use standard dimensions and textures when custom tool modifications are not necessary. This not only saves cost but also time
For instance, a medical device manufacturer saved up to $12,000 in tooling costs just by redesigning a housing component and eliminating side cores.
3. Invest in High-Quality, Durable Tools
Cheap things cost heavy in long run. Likewise, you may save upfront cost by choosing tools but there is high chance you need to high investment later as it demands frequent repairs, downtime, and part defects. Tools made from hardened steel (H13 or P20) are of high quality, last longer and produce identical parts consistently.
- Multi-Cavity Molds: By increasing number of cavities per cycle, per unit cost gets significantly down. For example, a 4-cavity mold can reduce per-unit costs by 40% compared to single-cavity.
- Conformal Cooling Channels: Conformal cooling is faster and uniform. It reduces cycle times by 15–30% for 3D-printed molds.
- Prevent Downtime: By scheduling regular cleaning of mold, proper lubrication, and inspections, you can avoid unwanted downtime.
In a case study on automotive supplier, it was found that they reduced annual repair costs by $50,000 because they switched to hardened steel molds with conformal cooling.
4. Leverage Automation
Automation is no more just a feature of large-scale manufacturers. IoT and robotics have become affordable for small to mid-sized companies also. If you belong to latter, adopt automation and cut labour costs, improve efficiency and productivity.
- Robotic Part Handling: Part removal and sorting can be automated to reduce labour and cycle times.
- AI-Powered Process Monitoring: Deviations like temperature drops can be detect by sensors in real time to minimize scrap.
- Predict Failures: IoT tools can predict mold failures even before they occur.
Stat: Manufacturers using AI-driven process optimization report 20–35% lower defect rates.
5. Optimize Cycle Times
Being extremely time sensitive process, cycle time directly impacts production costs in injection molding. Even a 5-second reduction per cycle can save your investment substantially. Therefore, cycle time optimization is a cost efficient strategy.
- Increase Cooling Efficiency: Use mold material with high conductivity or rapid-cooling technologies like pulsed cooling.
- Adjust Injection Speed: Fill the molds by thrusting faster. But don’t forget to optimize gate design to avoid jetting defects.
- Automate Post-Processing: Include post cooling process like trimming, drilling, or assembly into the molding cycle.
Extra Tip: Design of Experiments (DOE) is a reliable method to identify the optimal balance of temperature, pressure, and speed.
6. Source Locally
Offshore suppliers often charge lower labour rates. But additional costs like shipping delays, tariffs, quality issues can prove to be costlier than local suppliers.
- Fast Turnaround: Local suppliers can provide the material in fast turnaround time and minimum order quantities (MOQs) is also lower.
- Better Communication: Proximity to the supplier allows better communication. They also give access to onsite quality checks.
- Sustainability Goals: Aligning with ESG initiatives, local sourcing reduces net carbon footprint.
Example: A U.S.-based toy company reduced lead times by 6 weeks and saved $8/unit by switching to a local supplier.
7. Adopt Lean Manufacturing Principles
Reduce wait time, establish better communication channel between employees, reduce reworking, streamline production and avoid unnecessary plans. This methodology is known as lean manufacturing.
- Just-in-Time (JIT) Production: Produce what is required and keep the inventory to minimum.
- Energy-Efficient Machinery: All-electric or mechanical-electrical hybrid machines use 40-60% less energy than hydraulic presses.
- Employee Training: Cross-train staff to handle multiple roles, collaborate better and reduce idle time.
Stat: Lean practices can reduce operational costs by up to 10-20% annually.
Bonus Tip: Explore Alternative Technologies
Avoid high tooling costs by adopting 3D printing or urethane casting for prototypes or low-volume runs. While these cannot replace for injection molding, they can bridge the gap until full-scale production.
Conclusion
To reduce injection molding costs, it requires a fine balance of smart design-making, making best use of advanced technologies, and collaboration with experienced partners. At Northern Plastics, we specialize in manufacturing of injection molds as we implement automated tooling methods, optimize material sourcing, and implement lean production processes to get desired results at low production cost. By implementing these strategies, you stay ahead of the competitive curve in the challenging market in 2025.
Contact us today at info@northernplastics.in for a free project review and cost-saving analysis.
FAQs: Reducing Injection Molding Costs
Q: What is the biggest cost intensive aspect of injection molding?
A: Material costs (50-70%) and tooling (20-30%) are the largest expenses.
Q: Can I reduce cycle times without new equipment?
A: Yes. To optimize cycle time, use rapid cooling, injection speed, and integrate trimming and drilling into molding cycle.
Q: How much can DFM reduce tooling costs?
A: DFM is an efficient method where simplification of design lowers tooling expense by 20-30%.
Internal Links to Add:
- Injection Molding Services – Injection Molding – Northern Plastics
- Custom Tooling Solutions – Mould Design & Development – Northern Plastics
- Request a Quote – Contact Us – Northern Plastics
- Take a Virtual Tour of our factory – Factory Pictures