Plastic injection moulding is the backbone of high-volume toy manufacturing. Producing millions of identical, defect-free parts requires meticulous attention to tool steel selection, Design for Manufacturing (DFM) principles, and precise resin temperature regulation.
1. DFM Analysis & Multi-Cavity Mould Design
Before cutting tool steel, our engineers run 3D Moldflow simulations to optimize gate locations, eliminate weld line defects, and balance cavity pressure. Hardened tool steel grades (NAK80, S136, H13) are machined using high-precision CNC units to ensure up to 1,000,000 production cycles.
2. Food-Grade Polymer & Resin Processing
We process food-grade ABS, Polypropylene (PP), Polycarbonate (PC), and TPE resins with certified non-toxic masterbatch colorants. Controlled barrel temperatures and automated robotic part extraction guarantee uniform wall thickness, zero sink marks, and high tensile strength.
3. Surface Finishing & Decorative Coating
From high-gloss mirror polishes and tactile matte textures to automated multi-color pad printing and ultrasonic welding, our post-moulding finishing processes ensure your toys meet premium retail shelf standards.