Low-volume injection molding is a great way to save costs during design validation before mass production. However, how much does low-volume injection molding cost? This is a critical question when deciding to move forward with a low-volume injection molding project and setting the right budget before spending money.
This article will explain everything about injection molding costs and provide an overview of the general costs associated with a low-volume injection molding project. We will also share some helpful tips on how to reduce injection molding costs. Let’s dive in.
Factors of Costs in Low-volume Injection Molding
Generally, the cost of low-volume injection molding varies depending on the part and application. It can range from hundreds to thousands of dollars. In this article, we will explain all the factors that impact the price of injection molded parts.
Injection Tooling cost
Generally, the cost of rapid soft tooling for low-volume injection molding ranges from $200 to $2,000. However, this estimate is based on the assumption of simple plastic parts. For more complex parts, the tooling structure will be more intricate, often requiring lifters and slides, which increases the rapid tooling cost. Additionally, rapid tooling typically uses aluminum or soft steel as the tooling material, which is more affordable compared to hard steel.
Injection Molding process cost
hourly rate of the machine
Depending on the size of the plastic parts, an appropriate injection machine will be used. The larger the injection machine, the higher the cost will be for operating it. Once the injection machine is selected, the manufacturer can determine the hourly rate for using the machine. The more expensive the injection machine, the higher the hourly rate will be.
Cycle time
Cycle time refers to the time required to inject the plastic parts. Simpler and easier plastic parts will result in shorter cycle times. Cycle time is influenced by factors such as the injection machine, material, part geometry, cooling system, and time settings.
Labor cost
Labor cost is calculated based on the labor salary and the number of workers required for the injection molding operations. There is also an hourly rate for labor, and the time spent on the operation must be taken into account.
In summary, the cost of the injection molding process is calculated as follows: Machine hourly rate × Cycle time + Labor cost. Generally, for a simple plastic part, the injection molding process costs between $200 and $2,000.
Injection molding part material cost
The material cost of plastic parts includes all materials used in the injection molding process, such as the plastic part itself (including the injection gate) and the material used in the runner of the tooling. Material costs vary depending on the grade of plastic used for injection. Below, we provide a list of common injection molding materials and their associated costs.
| Material | Estimated Cost (USD/kg) |
| Polycarbonate | 3.00 – 6.50 |
| Acrylic | 2.50 – 4.00 |
| Polypropylene (PP) | 1.50 – 3.50 |
| ABS | 2.00 – 4.50 |
| Nylon | 2.80 – 5.00 |
| Polyethylene (PE) | 1.20 – 2.50 |
| Polyoxymethylene (POM) | 2.50 – 4.50 |
| Thermoplastic Polyurethane (TPU) | 3.00 – 6.00 |
In summary, the material cost of an injection molded part is calculated as follows: Material cost per kilogram × Part material weight. Generally, for a small and simple part, the total material cost for all production volumes (100-1,000 pieces) ranges from $100 to $1,000.
logistic cost
Logistic costs include shipping and packing expenses, which are particularly important when shipping overseas by air, as the cost can be high. Generally, for small-sized parts, logistics costs are around $0.50 per part.
How Is Injection Molding Parts Cost Calculated?
After considering all the factors above, the injection molding cost per part can be estimated by dividing the hourly rate by the number of parts molded per hour. The cost breakdown is as follows:
Part unit cost = Material cost + Processing cost + Tooling cost (amortized) + Packing and logistic cost.
However, this calculation only reflects the cost, without factoring in the margin. Each manufacturer has a different margin strategy, which can vary based on production volume.
Low volume Injection Mold Cost Overview
Low-volume plastic molding involves the production of parts ranging from a few hundred to a few thousand. On average, the total cost for low-volume injection molding of small and simple parts is between $500 and $5,000, including both tooling and injection molded part costs. For example, let’s assume the following conditions for a production run of 100 to 1,000 parts:
- Number of parts: 100 – 1,000
- Cost of the tooling: $200 – $2,000
- Total Cost of Materials: $100 – $1000
- Total Cost of Injection process: $200 – $2000
- Total Cost of Injection molded Parts: $500 – $5000
- Logistic cost per part: $0.5
- final Cost per Part: $5.5
Tips for Reducing Low Volume Injection Molding Cost?
Here are some tips based on our many years of experience:
- 1. Simplify part and Tooling Design
- 2. Reusing Molds if possible
- 2. Choose low-cost raw materials
- 3. Purchasing raw materials in bulk
- 4. Use Recycling materials
- 5. Improve production efficiency
- 6. Choose Insert Molding if two color part
Conclusion
Understanding injection molding costs and their calculation methods is crucial for optimizing the manufacturing process. This article has covered the key factors you need to understand about injection molding costs and how to manage them effectively. KUSLA is the right partner when you need prototype injection molding services. We offer high-quality, cost-effective rapid tooling and injection molded parts that meet your requirements.
