Fern Plastics

Plastic injection moulding is a fantastic tool to create dedicated items in large quantities for a low cost but choosing the right plastic injection moulding supplier is imperative to making your project a success. We talk you through the ways to choose the best plastic injection moulding supplier for your business needs.

Why is it Important to Choose the Right Plastic Injection Moulding Company?

When creating your plastic injection moulded product, it is important that you choose a company with experience in a range of fields that can do the job well the first time, if time is an issue for you, it is also important you choose a company with quick turnaround times to ensure you get your plastic injection moulding and plastic injection moulded product when you need it. If your injection moulding has technical aspects, experienced experts with high-tech equipment are essential.

What to Look at When Choosing a Plastic Injection Moulding Company

When looking at potential plastic injection moulding specialists, it can be hard to make the right decision. We’ve put together a few tips on what to look at when choosing the right injection moulding specialist for your project needs.

Specialist Industry Knowledge

Every industry is different, so having an injection moulding specialist can be incredibly helpful in identifying the unique issues and challenges your industry faces when it comes to creating plastic injection moulded products.

These specialists possess an in-depth understanding of material properties crucial for specific applications, which allows them to select the polymers that align with your product’s performance requirements. Additionally, their familiarity with industry regulations ensures that your moulded products adhere to the necessary standards and certifications. 

Injection moulding specialists also bring valuable insights into unique design details, so they can provide guidance on optimising moulds for enhanced functionality and cost-effectiveness within your industry. This targeted expertise not only enhances the manufacturing process but also contributes to the overall success of your moulded products giving you a competitive advantage over the competition.

State-of-the-Art Technology

State-of-the-art plastic injection mouldings require state-of-the-art machines. At Fern Plastics, we provide a wide range of intricate techniques with high-end machinery to create one-of-a-kind designs and finishes that perform under pressure.

As plastic manufacturers, our capabilities extend to advanced processes like gas-assist injection moulding that not only enhances the structural integrity of complex parts but also helps to reduce irregularities on the surface, sink marks and other cosmetic defects. This results in lighter yet robust components with superior surface finishes. Whether you require intricate designs or structural innovation, our cutting-edge technology ensures precision and efficiency in every aspect of your plastic injection moulding project.

Availability of Materials

When it comes to high-quality plastic injection moulds and plastic injection moulded products, quality materials are key. At Fern Plastics, our state-of-the-art Engel and Arburg machines melt a complete range of thermoplastic pellets to ensure the perfect combination for our injection moulded production.

With over 200 tonnes of readily available polymers in stock, we can meet your unique demands. Examples of thermoplastic materials we work with include versatile options like impact-resistant ABS (Acrylonitrile Butadiene Styrene), UV-resistant polyamide and lightweight polycarbonate. 

Additionally, we offer sustainable choices such as recycled ABS in black and variants, which aligns with our dedication to environmental responsibility. Our diverse thermoplastic material selection caters to a spectrum of industries, allowing us to tailor solutions that precisely match the requirements of your specific applications.

Quick Turnaround for Plastic Injection Moulded Products

If you are on a tight time schedule, one of the first things you should check with your prospective plastic injection moulding supplier is how quick their injection moulding time frame is. Some plastic injection moulding specialists such as Fern Plastics feature 24-hour production on 3 shifts for a fast response and short lead-times when creating your plastic injection mould and plastic injection moulded products.

With a robust project management approach, Fern Plastics ensures efficient coordination across shifts, streamlining the entire production process while maintaining the highest quality standards to meet your project deadlines effectively.

Design Capabilities for Injection Moulds

At Fern Plastics, we have vast experience creating bespoke plastic injection moulds for a range of industries. Our qualified technical staff use CAD design with mould flow analysis to assist with product and mould tool design whilst project managers take time to get to know your business needs to ensure a fully-customised design that works for your individual needs. Our in-house tool room is perfectly equipped for the manufacture, modification and repair of mould tools, jigs, fixtures and gauges with every element carefully considered.

Environmental Impact

In recent times, it has become more important than ever for brands and companies to consider their environmental impact. One of the easiest ways to limit your effect on the environment is to work with companies that also monitor their impact. As a company, sustainability is an important element of how we work. Alongside our aim to recycle up to 100% of our plastic waste, we also use recycled packaging and aim to swap out our single-use plastic tape for paper tape, you can read more about our environmental policy statement here.

In-House Tool Production

When it comes to creating the moulds and tools for your plastic injection mouldings and moulded products, keeping every aspect of the production together is the key to the smooth running of your project. Producing tooling in-house allows complete control over your finished product with the ability to adapt your design according to any necessary changes to the design and use. Our fully-equipped in-house tool room allows for complete control over the professional manufacture, modification and repair of mould tools, jigs, fixtures and gauges to keep your plastic injection moulding project running smoothly.

Additionally, Fern Plastics offers reshoring opportunities, allowing new customers to relocate the manufacturing of their plastic injection moulds to our facilities, further ensuring efficient production processes.

Quality Finishes

When it comes to the production of plastic injection moulded products, the moulding is just the first step towards a finished product. Plastic injection moulded products often have a range of finishes to help them look the part. This could include elements such as paint finishes, chrome plating on highly polished ABS polymers or even insert or over moulding to create independent parts to your plastic injection moulding, all of which can be performed in-house by our specialist team. 

If you require laser marking such as indelible marking or etching for example for medical instruments, expert pad printing or any other type of high-quality finish, it is important that you check this is a service your plastic injection moulding specialist can provide before signing the dotted line.

Now you have an idea of what you need to consider when choosing the right injection moulding company, you can improve your chances of having a successful project from start to finish. Whether you are looking to move your custom plastic molding  production to another company or you’re looking for sustainable injection moulding options, Fern Plastics offers you a comprehensive service at competitive rates. For more information about our services, contact our team of experts today.

When it comes to plastic moulded products, two main moulding methods are often discussed, plastic injection moulding and vacuum moulding. But what is the difference between plastic injection moulding and vacuum moulding? We go into the differences between the two plastic moulding types and more.

What is Plastic Injection Moulding?

Plastic injection moulding is the process of injecting molten plastic into a pre-designed mould in order to create a plastic moulded product. By injecting molten plastic into a mould at high pressure, the plastic is forced to fill the gaps in the mould and create the shape of the mould design. Once the plastic has cooled, the mould is opened and the plastic injected products are removed from the moulding machine. 

What Type of Products Are Made From Plastic Injection Moulding?

Plastic injected products can be found everywhere in the home and beyond. Plastic injection moulding is often used to produce items such as recycling bins, medical tools, car parts, toys and more with the ability to highly customise the plastic mould meaning that a wide range of intricate designs can be produced in numerous quantities.

What is Vacuum Moulding?

Vacuum moulding, also known as thermoforming, is a process during which a heated sheet of plastic is stretched over a vacuum forming tool in order to form a plastic part. The thermoforming plastic sheet forms the shape of the mould through a vacuum process and as the sheet cools it forms a hard shape before the moulding tool is removed.

Here’s how the thermoforming process works:

• Preparation – A flat sheet of thermoforming plastic is clamped into a frame. The type of plastic chosen depends on the specific requirements of the part being produced.
• Heating – The sheet is then heated until it becomes soft and pliable. The temperature and heating time vary depending on the material’s thickness and type.
• Moulding – After the thermoplastic sheet is heated to the desired temperature, it is quickly moved to the mould or tool.
• Thermoforming – Once the heated sheet is in position over the vacuum-forming tool, a vacuum is applied beneath the mould, which suctions the plastic sheet tightly against the mould’s surface. This forms the plastic into the shape of the mould. Any excess material is trimmed away.
• Cooling and Release – After the plastic has taken the shape of the mould, it is cooled. Once it has cooled and solidified, the vacuum is released and the formed plastic part can be removed from the mould.

What Type of Products Are Made From Vacuum Moulding?

Depending on the design of the plastic moulding, vacuum moulding can create a variety of designs and styles. Items such as plastic bathtubs, garden equipment and plastic utensils can be made using the vacuum moulding process.

Plastic Injection Moulding Vs Vacuum Moulding, Which is Best?

When it comes to plastic formed products, each technique is different. For tight tolerances, plastic injection moulding is often more suitable than vacuum forming whilst the plastic injection process can also often work out as cheaper than the vacuum moulding process, particularly for larger projects where a high volume of plastic injected products need to be formed. The process of vacuum forming is sometimes also less controlled than plastic injection moulding die to the heated plastic being stretched over a mould.

What are the Advantages of Injection Moulding Compared to Vacuum Moulding?

There are a few advantages to using plastic injection moulding when compared to vacuum moulding.

High precision and tight tolerances – Plastic injection moulding allows for the production of parts with extremely tight tolerances and high precision. This process is capable of producing complex, intricate parts with consistent wall thickness, intricate details and minimal variations. In contrast, vacuum forming may have some limitations in achieving the same level of precision due to the stretching of the heated plastic sheet over the mould.

Higher production volumes –  Injection moulding is better suited to high-volume production runs when compared to vacuum moulding. The cycle times in injection moulding are typically faster than vacuum forming, and the process can produce a large number of parts in a shorter period of time. This efficiency makes it more cost-effective for long production runs

Material selection – Plastic injection moulding allows for the use of a range of thermoplastic materials including high-performance engineering plastics like Acrylonitrile Butadiene Styrene (ABS), Nylon (PA) and Polycarbonate (PC). This means that injection-moulded parts can have superior properties such as heat resistance, greater strength, chemical resistance and more. Injection moulding is often chosen when the application demands specific material characteristics and performance.

Plastic Injection Moulding Specialists

As plastic injection moulding specialists, we offer a wide range of plastic injection moulding services to help bring your project to life. We have a number of years experience and have faced every challenge there is in terms of plastic injection moulds so are perfectly placed to answer any questions you may have.

Contact our team now on 01902 758282 to find out more about the range of plastic injection moulding services and related services we offer and talk to our specialists.

When it comes to manufacturing quality plastic injection moulded products, we are experts in our field. From the smallest, intricate part to large, mass-produced plastic moulded projects, we have experience and skills to perfect your products. When it comes to plastic injection moulding, there will always be risks of defects in the finished product. Here are just some of the ways we avoid injection molding defects in our injection moulding process using high-tech machinery and skills to create your perfect product.

Avoiding Air Pockets and Vacuum Voids During the Plastic Injection Moulding Process

When creating bespoke products using plastic injection moulding, it is extremely important to avoid the creation of air pockets during the process. A bubble defect in injection molding can be the result of volatiles from the resin, the decomposition of gases from polymers or additives or moisture vapour. This can inadvertently distort the shape and use of the finished product. As experts in our field, we have a number of processes in place to avoid this in our plastics mould manufacturing process. We also have high-tech machinery to optimise the process and ensure adequate moulding pressure forces any excess air out of the moulding cavity. Our high-tech plastic injection moulding machinery also ensures premature cooling does not happen, another cause of air pockets in the moulding process.

Preventing Burn Marks in Our Plastic Injection Moulding Process

In some cases when creating plastic injection moulded products, burning can appear. In many cases, this can be due to air or even resin becoming trapped in an air cavity and overheating. This then results in the scorched material. Here at Fern Plastics, our skilled team members prevent burn marks in injection molding by loosely monitoring the temperature of our plastic injection mouldings and the speed of our injection mouldings to ensure this doesn’t happen to our products. We take pride in ensuring each of the products that leave us are fit for purpose and look visually as expected..

Avoiding Plastic Injection Mould Warping

As with any materials, when treating plastics and using them during the plastic injection moulding process, there is a risk of warping the materials. A warping defect in injection molding has a range of side effects including excessive space produced between components and misshaped products. Warping as an effect of the injection moulding process can be caused during the cooling process when uneven shrinkage can put stress on different parts of the plastic product. Often, the materials used can be prone to developing warping defects. Materials with semi-crystalline structures are more likely to be subject to warping. We combat this through strategic selection of materials and expert mould design to avoid this. We also ensure an even and gradual cooling process to avoid warping of the plastic injection moulded product.

Jetting During the Plastic Moulding Process

A jetting defect in injection molding can occur when the solidification process happens unevenly. In order to create a smooth, streamlined plastic injection moulding without any jetting, it is important to use the perfect injection pressure for your product to avoid initial streams solidifying before the product is finished. We have years of experience perfecting the plastic injection moulding process so make it our priority to provide an exceptional product and service each and every time. Our innovative machinery calculates the exact pressure needed for every moulding whilst our mould designs optimise for a smooth finish.

Preventing Sink Marks in Injection Molding

Sink marks are common defects in injection moulding often found in thick-walled sections. One of the main causes of sink mark defects relates to incorrect melt temperatures. We are able to prevent the formation of this defect by understanding the importance of staying within the temperature range recommended by the resin manufacturer. Since thick sections contain more plastic, failing to verify the temperature can result in the part taking longer to cool which will lead to the formation of sink marks. As well as verifying the correct temperature during the injection moulding process, we make sure the correct second-stage pressure and pack and hold times are maintained. The ideal second-stage pressure (or pack and hold pressure) not only helps to prevent shrinkage but when combined with the proper pack and hold times, ensures the part is efficiently sealed which can prevent sink marks from forming. Where applicable, we apply gas-assist injection moulding processes to help reduce the appearance of sink marks.

Avoiding Short Shots in Injection Molding

During the injection molding process, partially formed parts known as short shots occur when the resin hasn’t entirely filled the mold cavity. The result is a plastic part that is visibly incomplete and often unusable. We prevent short shots in injection molding by ensuring a consistent flow within the mold cavity which can be affected by blocked or narrowed gates. We also avoid short shots by adjusting the mold temperature and maintaining the correct injection pressure so that the entire mold cavity is filled during mould injection. 

Weld Lines in Injection Molding

A weld line defect is formed when two flows of injected resin material meet within the mould cavity. Also called a “knit line”, these marks usually form around holes as the plastic flows around either side. When the temperature of the resin is incorrect, the two flows fail to bond together properly which results in a visible weld line. Weld line defects reduce the durability, strength and aesthetic quality of the plastic component. To combat the formation of a weld line defect in injection molding, we can make adjustments to the mould design as well as raise the temperature of the molten resin which prevents it from solidifying too fast. Low-viscosity resins with lower melting points are often less prone to developing weld line defects. We also adjust the injection speed and pressure where necessary which also prevents early solidification and the formation of knit lines. 

Our experienced and highly trained team are fully equipped to deal with the nuances of plastic injection moulding to ensure an industry-leading product each and every time. If you are looking for state-of-the-art plastic injection mouldings from a source you can trust, get in touch with the team here at Fern Plastics and find out more about what we can offer you. Get in touch online or call 01902 758282 for more.

Plastic injection moulding is one of the most efficient and cost-friendly plastic product production processes. Countless household and business products are formed from plastic injection moulding, perhaps even items you didn’t think were injection moulded. We talk through why plastic injection moulding is so effective.

What is the Plastic Injection Process?

Plastic injection moulding is conducted through precisely injecting molten plastic at pressure into a specially-designed mould. Once the molten plastic cools, a firm product is produced that can stand the test of time. Over moulding and other processes can be used to create more bespoke, intricate plastic injection moulded designs that work for a variety of purposes.

Why is Plastic Injection Moulding So Effective?

Fewer plastic production processes are as effective as plastic injection moulding. One of the main reasons for this is the impressive cost-effectiveness plastic injection moulding enjoys. Injection moulding can produce high volumes of identical products with ease and with a much quicker turnaround than other plastic moulding processes. The efficiency of the injection moulding process is also a factor in the fantastic cost-effectiveness of plastic injection moulding. Once the specialised injection mould has been designed and created by our in-house experts, that same mould can be used countless times, producing plastic injected products with ease at very little cost per item.

Fast, Efficient Plastic Injection Moulding

Our state-of-the-art plastic injection moulding machines work round the clock to ensure high-speed plastic product production that doesn’t compromise on quality or design. The efficiency of custom plastic mouldings results in low labour costs and lower end costs with the ability to use multiple types of plastic within the injection moulded products.

Strong, Fit-for-Purpose Design

The nature of the plastic injection moulding process makes it ideally adaptable for all manner of purposes. From household objects to car parts to medical equipment, plastic injection moulded products can be designed with a number of parts and features to fit a range of uses. Multiple type of plastic can be combined within the injection moulding to form a bespoke product with intricate details and complex shapes repeated time and again for each and every plastic injection moulded product. The ability to create custom plastic mouldings with ease is one of the ways plastic injection moulding is so effective.

Plastic Injection Moulding Specialists

When it comes to ensuring an effective plastic injection moulding process, Fern Plastics are leaders in their industry. Crafting bespoke plastic mouldings using time-honed skills and state-of-the-art technology Fern Plastics can create intricate designs and parts with extremely close consistencies. To find out more about our plastic injection services, contact our team now on 01902 758282.

The process of plastic injection moulding is a fantastic way to produce high quantities of perfectly replicated products for a relatively low cost. At Fern Plastics, we have been specialists in plastic injection moulding for a number of years so know how to get the very best out of the process. We always assign a project manager to each of our plastic injection mould projects to ensure they are the most effective moulded projects they can be. Here’s why we think having a project manager for plastic injection moulding is a key part of our success.

Coordinated and Coherent Injection Moulding Management

We know that every project is important when it comes to plastic injection moulding, that’s why we only work with skilled and experienced individuals we know will get the job done right the first time. Our fully-trained, qualified and experienced plastic injection moulding specialists will involve themselves in your project from the first inception to the final finished product to ensure it is effective and as promised. Our injection moulding project managers have seen every challenge our customers face and know the best ways to get the most out of the plastic injection moulding process so are perfectly placed to advise and answer any questions you may have.

Effective Products

We know that no two projects are the same with each product offering a unique set of challenges and needs. Your dedicated project manager will work to understand every requirement and use of your plastic injection mould to ensure an effective product every time. Our fully-equipped in-house tool room provides the perfect space for the manufacture, repair and modification of mould tools, gauges, jigs and fixtures to keep them fit for purpose with a team of specialists on board to make your project a success,

What Our Plastic Injection Moulding Specialists Provide

Our experienced and fully-trained project managers can offer design failure mode and effects analysis (DFMEA) and Advanced Product Quality Planning (APQP) to full Production Part Approval processes (PPAP) along with CAD and mould flow analysis to assist with product and mould tool design to ensure your plastic injection moulded product can meet whatever demands are thrown at it.

Our unique long-standing relationships with a selection of low-cost economy tool makers also ensure that projects are completed on-budget. With knowledge of each of the specialist services we supply here at Fern Plastics, your plastic injection moulding project manager is perfectly placed to advise on every aspect of our business and your project to ensure it is the best it can be and performs as efficiently as possible.

Specialist Services and Advice for Every Project

If you are looking for a specialist plastic injection moulding service with a difference, Fern Plastics are here to help. Our knowledgeable team have created injection moulds for a wide range of industries and uses from medical tools to car parts, toys and everything in-between and are committed to fast, reliable service to fit your budget.

To find out more about our plastic injection moulding service, contact Fern Plastics now online or by calling 01902 758282.

When it comes to plastic injection moulded products, quality and expertise are key. Fern Plastics have a number of years of experience in plastic injection moulding making us leaders in our industry. From technical know-how to state-of-the-art technology, we tell you what makes us specialists in our field.

Specialists in Highly-Technical Plastic Injection Mouldings

Whatever your project, we have the expertise to bring it to life. Over the years we have worked with individuals and companies from all types of industries with no project too big to set our minds to. Our state-of-the-art Engel and Arburg machines can melt a full range of thermoplastic pellets before injecting them into intricate custom moulds for impeccable product quality.

Over 60 Years in the Injection Moulding Industry

We’ve spent over 60 years being experts in our field so are confident that whatever project you have, we have the tools and the expertise to help. We’ve created a number of highly-bespoke and intricate plastic injection mouldings and moulded parts over the years so have learned the particular nuances of the trade.

High-Precision Moulds to Close Tolerances Every Time

Fern Plastics are specialists in technically challenging plastic injection mouldings with outstanding specifications for leak-free and pressure-tight plastic injection mouldings. We’ve built up a reputation so that you can be assured your injection mouldings will be right first time every time. Our gas injection mouldings improve aesthetics and reduce the material content in thicker sections for accuracy.

Efficient Plastic Injection Mouldings That Don’t Compromise on Quality

Fern Plastics operates a 24-hour production on three shifts in order to respond fast to demand and create short lead times for all of our plastic injection mouldings. Our 6-axis robots ensure consistent cycling and improve both productivity and quality whilst our experts can create insert mouldings or over mouldings which include two or materials for complete flexibility.

Value-Added Services to Create a Superior Product

Alongside our standard plastic injection moulding services, Fern Plastics also provide a wide range of added services to ensure a superior product and complete flexibility when it comes to the useability of your product. To find out more about our added services, take a look at the blog.

Contact the Plastic Injection Moulding Specialists

Whatever your project, our team of highly specialised experts are ready to make your project a success. We always deliver on time and pride ourselves on creating the highest-quality product to extremely close consistencies each and every time. We can provide specialist injection mould services no matter how big or small the project.

To find out more about how we can help bring your plastic injection moulding ideas to life, contact our team now.

Established in 1959, Fern Plastics is a Wolverhampton-based company providing plastic injection moulding and more. Our well-trained workforce is highly motivated to supply customers in the UK and Europe from our modern and efficient purpose-built plant based on a prime 9000 m2 site in Wolverhampton. As a proud West-Midlands plastic injection moulding company, our primary objective is to retain and increase the company’s strength and security whilst providing an unparalleled service to every one of our valued customers. Over the years, we have established ourselves a great reputation for innovation and flexibility in the industry and we are widely recognised by our loyal customers. 

For added peace of mind and confidence, our quality and environmental management systems are independently accredited to ISO9000 and ISO14001 respectively. 

What Do Fern Plastics Do?

At Fern Plastics we create bespoke plastic injection moulding solutions for a range of industries. We are proud to include a number of very demanding ‘blue-chip’ international customers in our portfolio and strive to provide world-class service to each and every customer. Our modern Arburg and Engel plastic injection moulding machines produce high-quality, technical plastic injection mouldings with close precision, accuracy and repeatability up to 2.5kg in all thermoplastics and finishes.

We are proven to be agile and cost-effective service with 24-hour production for short lead times. We have the capability to make new, cost-efficient, custom moulds or transfer your existing moulds to us for a reliable and responsive production service for both small or large quantities. 

We are with you every step of the way from concept through production even supporting spare parts legacies. Supporting you with material selection, problem-solving and DFM our excellent new product introduction process and superb project management will be executed by our incredibly knowledgeable, experienced team. You are in safe hands. 

Value-Added Services from Fern Plastics

Whilst we are industry leaders in plastic injection mouldings, our fantastic service doesn’t stop there. We also provide a range of essential, complementary services for your business. These include:

• Gas-Assisted Injection Moulding
• Insert Moulding / Over-Moulding
• Ultrasonic Welding and Heat Welding
• Assembly and Testing
• Tampo Printing / Pad Printing
• Laser Marking
• Decorative and Resistant Finishes
• Just-in-Time Logistics

Where Are Fern Plastics Based?

Our team of highly-trained, qualified and experienced technical staff primarily work from our purpose-built Wolverhampton factory in the West Midlands. Fern Plastics injection moulding conveniently sits close to the M6 and M54 motorways and is just 15 minutes away from the main Wolverhampton railway station. Three major international airports are also less than an hour away from our Wolverhampton factory site.

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Get in Touch

Contact us now on 01902 758282 to discuss how we can help your business thrive or get in touch via the website to send us an email.