What is the life expectancy of a plastic injection mold?
The life expectancy of a plastic injection mold typically ranges from 100,000 to over 1 million cycles, depending on several factors including mold material (steel vs. aluminum), part complexity, production volume, maintenance practices, and the type of resin being molded. High-quality steel molds maintained properly can last decades in production environments. At Evok Polymers, we design tooling with longevity in mind and provide guidance on maintenance schedules to maximize your mold's lifespan and return on investment.
How long does the injection molding process take from concept to production?
Our 5-stage development pipeline typically takes 12-20 weeks from initial concept to full production, depending on part complexity and tooling requirements. This includes concept feasibility (1-2 weeks), alpha research with prototyping (2-4 weeks), beta development with single cavity tooling (4-6 weeks), qualifications and production tooling (3-5 weeks), and final product launch preparation (2-3 weeks). We focus on speed to market while maintaining rigorous quality standards.
What types of materials can you work with for injection molding?
We work with a comprehensive range of thermoplastic materials including commodity resins (PP, PE, PS), engineering plastics (ABS, PC, Nylon, POM), high-performance polymers (PEEK, PEI), and specialty materials with specific properties like UV resistance, flame retardancy, or medical-grade certifications. Our material selection service helps you navigate material science to identify the optimal resin for your application's performance requirements and cost targets.
How much does injection molding tooling cost?
Tooling costs vary significantly based on part size, complexity, cavity count, and production volume requirements. Single cavity prototype tools may range from $3,000-$15,000, while multi-cavity production molds can range from $15,000-$100,000+. At Evok Polymers, we're very upfront with costs from the start, providing detailed pricing breakdowns so you can make informed decisions. We focus on building the most cost-effective tooling solution that meets your quality and volume needs while optimizing long-term part pricing.
What is your minimum order quantity for injection molded parts?
Our minimum order quantities are flexible and depend on the specific project, tooling investment, and part complexity. For prototype runs, we can produce as few as 50-100 parts. For production tooling, typical minimum runs start at 1,000-5,000 parts, but we work with each customer to determine the most economical order quantity based on setup costs, cycle times, and your inventory needs. We're committed to finding solutions that work for businesses of all sizes.
Do you offer design assistance for injection molding?
Absolutely. Our comprehensive CAD design services ($110/hour) include reviewing and modifying your files for mold-ready design for manufacturing. We can start with your 3D file or model from scratch in SOLIDWORKS. Our team implements changes for moldability, optimizes wall thickness, addresses gate and vent sizing, and provides detailed redlining documentation. We work iteratively with you through review/repeat/recycle cycles until your design is fully optimized for production.
How do you ensure quality in injection molded parts?
Quality assurance is built into every stage of our process. We conduct molding trial reports evaluating T1 samples before texturing, closely monitoring mold fill speed, knit line locations, zone temperatures, and cycle time. Our first article qualification includes 30 inspection points per cavity for critical dimensions and 5 points for non-critical dimensions. We provide comprehensive data on process variation (Cp and Cpk) and work hand-in-hand with customers to negotiate achievable tolerances. Our Six Sigma black belt certification ensures rigorous process control throughout production.
Can you help with prototyping before committing to production tooling?
Yes, rapid prototyping is a core service we strongly recommend. Our prototype services ($100-$500 per prototype depending on size and system) allow you to validate final designs for both structural and cosmetic verification before investing in production tooling. We help you choose the right rapid prototype process—whether 3D printing, CNC machining, or other methods—to advance your design with either cosmetic or functional prototypes. Seeing your part during development significantly reduces risk and ensures production success.