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3d-printer

Advanced 3D Printing Technology

We provide 3D printing service in technologies like FDM, SLS,SLA , MJM, MJF, PolyJet, DMLS, SLM etc.

on time project delivery


With locations in all over Australia we can assure lightning fast delivery.

Australia wide expandation


Zeal 3D Printing is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

Experienced Engineers


Team of expert engineers with more than 10 years of experience in prototyping.

ISO 9001 : 2015

ISO 9001-2015 certified


Committed to consistently provide products and services that meet customer and regulatory requirements and to demonstrate continuous improvement.

Injection Molding Services

Zeal 3D Printing Services offers comprehensive services for prototyping and producing parts through a plastic injection molding process. We have advanced machines, skills, and experience to design and manufacture injection-molded plastic parts. Our plastic injection molding services are suitable for a variety of industries for designing and manufacturing high-quality plastic products for both high-volume and low-quantity parts production. We manufacture and supply durable, functional, and cost-effective plastic injection molded products defence, automotive, medical, aerospace, and consumer industries. We are among the best plastic injection molding companies that offer an amazing range of services for the Australian and overseas market.

Being a leading provider of injection molding service, we offer a wide range of manufacturing services to OEMs. From gears to brackets, enclosures, knobs, pulleys, automobile parts, toy parts, robot parts, etc., we make thousands of molded plastic parts. We also offer an online injection molding service for which you just need to load your 2D or 3D CAD file on our website for an instant free quote. We provide free design assistance for our clients who needs alteration in the design of their product for Injection Molding.

Materials Used for Injection Molding

We have a wide range of materials available for injection molding like ABS, Acetal, Nylon 6/6, PEI (Ultem), PET, Polyethylene, Polypropylene, Styrene (crystal clear and opaque), TPE, etc. The selection of material from the wide range of different grades of these materials can be a challenging task but our team of expert engineers will help you to select the most suitable material for your application. Along with the different material options we provide different finishing options like painting in multicolor, glossy/matte finish, perforated finish, water transfer, electroplating, etc.

Accuracy:

Accuracy of final injection molded products depends upon the various factors like material, tooling, the geometry of the product, and surface finishes. The possible tolerance of most thermoplastic is ±0.2 to 0.5mm.in few specialized applications tolerances are low as ±5 µm on both diameters and linear features are achieved in mass production Surface finishes of 0.0500 to 0.1000 µm or better can be obtained. Rough or pebbled surfaces are also possible.

Application of Injection Molding

Injection molding is used to create many things, one of the most common is the plastic housing. These housings are used in a variety of products including household appliances, consumer electronics, power tools, and as automotive dashboards.

Injection molding is also used for medical devices, mechanical parts (including gears), and most other plastic products available today.

When you want to manufacture high volumes of the same object with plastic, Injection molding may be the ideal choice for it. Variety of products are manufactured with injection molding, which vary greatly in their size, complexity, and application.

Our Product and Services

If you are launching a new automobile and need custom product designs, we have the best custom injection molding expertise and services. Our industrial plastic parts designs are also utilized by building and construction, food packaging, and medical industries. Whenever think about Injection Molding services, think of the largest plastic injection molding company in the world i.e Zeal 3D Printing.

We are proud of being one of the top custom injection molding suppliers for manufacturers whose injection molding cost is lower than any market. Our team is skilled in producing high-precision and durable plastic injection molded parts. We work with advanced machines to handle our customers' needs for injection-molded parts from low to moderate, and large quantities in any 2D and 3D shapes. Whether you want to turn concepts into reality, enhance product design, or conduct injection molding and testing, we can provide a high degree of precision and aesthetic appearance to meet international standards.

Plastic injection molding service

Plastic injection molding is a faster and low-cost manufacturing process for quality and functional plastic products for a variety of uses across all industries. Our designers are experts in creating 3D CAD models with complex features and using laser-based rapid prototyping methods. We recommend all our clients to get prototype injection molding to test fitting and functionality before going for production. Easy testing, assembling, and manufacturing are various advantages of rapid prototyping.

Zeal 3D Printing is an expert in prototype injection molding and has the capacity to join fast prototyping procedures with ultimate ease. From high customization to complex design manufacturing, we do it all for you. We offer the best plastic mold manufacturing services for your every need. Search plastic injection molding companies near me and you will find Zeal to helping you about everything which you need to know about it.

A Few Advantages of our Plastic Injection Molding Services Include:
  1. No Limits on reproduction depending upon mold
  2. Dependability in parts conveyance
  3. High efficiency with complex geometries
  4. Full scope of tooling abilities

Enhanced strength and reduced manufacturing costs.

Zeal Injection Molding Services and plastic molding manufacturing services additionally offers its clients an extensive variety of auxiliary administration alternatives that incorporate machining, powder covering, silk screening, painting and ultrasonic welding. Zeal Injection Molding Services utilizes the most recent machines to deliver high-quality plastic products.

Metal Injection Molding

Metal injection molding is an advanced variation of conventional plastic injection molding that allows engineers to perform fabrication of solid metal parts. In this metal molding process, the raw material called feedstock is the powder of metal and polymer.

In this process, manufacturers utilize a standard injection molding machine, and the powder is melted before injecting into the mold. The powder cools down and solidifies into the desired shape during this process. After this, the heating process removes the unnecessary polymer to produce high-density metal objects.

This process is ideal for producing high-volume small metal parts with complex geometric designs. Metal injection molding can efficiently create objects with thin walls. Engineers can use a variety of ferrous and non-ferrous alloys and get the desired material properties. Our metal injection molding machine offers a tolerance level of up to ± 0.005 in and Max wall thickness of 0.04 to 0.25 in.

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Metals used for MIM parts:

Several industries including automotive, aerospace, and medical use robust metal parts manufactured using the metal injection molding process. Below are some of the commonly used metals used in MIM parts:

  • Stainless steel
  • Copper alloys
  • Titanium alloys
  • Nickel alloys
  • Tungsten alloys
  • Iron
  • Cobalt alloys, and many more

Zeal 3D Printing is among the leading metal injection molding companies that cater to all your bespoke manufacturing requirements with ease.

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Metal Injection Molding
Metal Injection Molding Process

Metal injection molding process consists of four significant production steps that turn powder from raw materials into a robust solid object. The process has the following steps:

Preparation of feedstock:

The first step of metal injection molding is to form a powder mixture of metal and polymer, and the metal used in this process is much more refined (under 20 microns). The powdered metal is mixed with a heated thermoplastic binder, cooled, and then pulverised into a feedstock in pellets. The end feedstock consists of 60% of metal and 40% polymer.

Injection molding:

Next, the powder is molded utilising the same machine and tooling that engineers use in plastic injection molding. But in this method, the cavities are 20% larger to manage the part shrinkage during the sintering process. In the process, the machine first melts the feedstock and injects it into the mold cavity, where it cools and gets the desired shape.

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Debinding:

In this step, the machine removes the polymer binder from the metal, and in many cases, engineers use solvent debinding to dissolve most of the binder. Once this step is complete, engineers perform the thermal debinding process. In this process, the molds are heated at a low temperature, and it helps in removing the polymer binder through evaporation.

Sintering:

The final step of this process includes sintering the remaining part at high temperatures (up to 1350°C) to reduce the space by around 1% to 5%, and it results in a high-density metal part. The furnace leverages inert gas to attaint's temperature of about 85% of the metal's melting point. This process helps remove pores and causes the part to shrink by 80% of its molded volume. The final part retains the original shape with higher tolerance levels.

Injection Molding Design Rules

Even while using 3d printed injection mold for the MIM process, most of the rules are similar to the plastic injection molding. But, here are some additions that engineers need to follow:

Wall Thickness:

The wall thickness should be minimal, and it should be uniform throughout the part production. Minimising the wall thickness helps in reducing material volume and sintering times.

Draft:

Unlike the traditional plastic molding process, MPM parts don't require any draft. The polymer binder that is used in the powder material releases quickly from the mold.

Sintering support:

While performing sintering, the MIM parts need robust support, or the parts will get distorted as they shrink during the process. Engineering can use standard flat support trays or use custom supports if required.

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Rubber Molding

Rubber molding is a molding process that manufactures usable rubber items produced from uncured elastomers or rubber. Elastomer is any rubber molding materials that have good resilience for returning to the original shape when applied.

Rubber molding process

The rubber molding machine creates molded rubber parts by hard pressing a rubber's block into a molding metal cavity. When the rubber is exposed to heat, it activates a chemical reaction, and there are several variations in this process to achieve the desired quality. The most popular variation methods are compression molding, transfer molding, and injection molding.

Types of rubber molding

Industries use several rubber molding solutions to accomplish respective structure and properties in the final product. There are majorly three types of rubber molding that are:

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    1. 1. Rubber compression molding

In this process, engineers keep a fixed amount of rubber compound into the mold cavity and then compress it into the shape of the cavity by closing both sides of the mold. In this process, the pressure remains the same while the heat is added to cure the product. Once the process is complete, engineers remove the final product from the mold.

    1. 2. Rubber injection molding

In this process, the rubber is heated to a liquid stage before injecting it into the mold. The final product is obtained by opening the mod and then closing it to get the following injection process for producing molding rubber.

    1. 3. Rubber transfer molding

In rubber transfer molding, the rubber compound is placed at a specific part of a mold called a pot before being pushed against a cavity to get the desired shape. Once the curing process is done, the mold is split while relating the product.

Rubber molding materials

There is a wide range of rubber molding materials available in the market to accomplish different tasks. Some of the popular ones are:

  • Nitrile or Buna-N
  • Hydrogenated Nitrile
  • Ethylene Propylene Diene Monomer
  • Silicone
  • Natural Rubber

Advantages of rubber molding

  • Good surface finish
  • Dimensional stability
  • Ethylene Robust mechanical properties
  • Suitable for parts with a large cross-section
  • Tooling is easy & cost-effective

Zeal 3D Printing is a leading rubber and silicone injection molding company that brings in the complete range of molding across industries.

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Rubber Molding
Foam Injection Molding

The foam injection molding process is a low-pressure injection molding process in which the machine introduces inter gases into the melted polymer to reduce the density of the product. The structural foam molding creates products that have cellular cores surrounded by integral and rigid skin. While making the homogenous mixture of polymer and gas, engineers use foaming agents, including NI, CO2, or CBA.

The foam injection molding machine then injected the material through the nozzle into the mold in a lower volume than the amount required to mold an object. Injection expansion and pressure of the polymer and gas then fills the mold. A porous surface is formed when the melt comes in contact with the cold surface of the mold. Then the foam injection molding expanding polymer mixture forms the cellular core.

Why use foam injection molding?

The foam molding process is an ideal process for producing high-strength, lightweight parts. Many large-sized objects require thick walls than conventional injection molding, making the production more accessible. The structural foam brings a quick turnaround while working with thicker parts.

Another benefit of leveraging this technology is that it's a very cost-effective molding process that produces robust products. With minimum warpage, the parts have superior durability.

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Structural foam injection molding advantages

  • It reduced molding costs

  • Complex product design capabilities

  • Improved dimensional stability

  • Highly efficient and cost-effective

  • Less material usage

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Micro Injection Molding

Micro molding is an advanced and highly specialized manufacturing method that can produce tiny plastic components with extreme intricate geometries. This process can manufacture parts weighing from 0.1gm to 1gm and tolerance levels of 10 to 100 microns.

It is an ideal method for producing tiny components with higher design precision and accuracy. This mini injection molding begins with creating smaller cavities to form the desired shape. Resin or thermoplastics are rapidly injected into the cavity to form components at a higher speed.

Industries using Micro Injection Molding Service

Several industries including, medical, automotive, and electronics manufacturing, require small injection molding processes to create minuscule parts. Following are some of the sectors using micro molding:

  • Automotive
  • Healthcare
  • Electronics
  • Pharmaceutical
  • Fashion

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Micro Molding Materials

  • Polypropylene
  • Polyethylene
  • Nylon
  • Polysulfone
  • Polycarbonate
  • Acrylics
  • Polybutylene terephthalate

Zeal 3d Printing is a leading micro injection molding company that caters to all industrial requirements with higher accuracy and shorter turnaround time.

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