From design to product: developing a plastic injection molded part

Developing a plastic product is a complex process that requires technical skills, foresight, and an integrated view of design, mold manufacture, injection molding and assembly.

EPS generates pathways that evolve into new components similar to an ecosystem, where each phase supports the next and contributes to creating solutions that are more efficient, sustainable, and aligned with the needs of the target market.

Design: where innovation begins

Knowing plastic materials and working across the entire production chain, from equipment design to applying different finishes on molded parts, allows EPS to adopt an approach that considers all key aspects of a project from the very first feasibility analysis. Design is the starting point of every new plastic part and begins with:

• Functional analysis: evaluating the product’s function and lifecycle to define technical and aesthetic requirements, mechanical loads and usage conditions.
• R&D and co-design: working with the customer to anticipate issues and optimize geometry, materials, and processes. Developing solutions not yet available on the market also enables the creation of innovative parts or the conversion of metal components into plastic.
• Advanced simulations: DFM and moldflow analyses to assess filling and deformation, ensuring quality and repeatability.

Molds: precision, reliability, durability

The mold is the tool that gives shape to a plastic part. It is a key element of the production cycle because it must ensure dimensional stability over time, reduced cycle times, easy maintenance and compatibility of steels with engineering polymers or recycled plastics.

When to choose 3D additive manufacturing, a rapid tooling, or a full injection mold?

The choice depends on the plastic material, production volumes, and part characteristics. Some projects require all three technologies, used respectively for early feasibility, pre-series molding, and mass production. EPS supports each project by advising on every technology it can provide.

Key aspects in designing an injection mold

Developing a plastic product requires an integrated view of design, mold manufacture, molding and assembly. EPS’s technical team evaluates from the earliest stages:

• industrialization aspects
• selection of suitable materials for technical, aesthetics and sustainable performance
• factors affecting the quality of the molded part
• checks and requirements related to finishing and assemblies

Advanced polymers can now be used for high temperature resistance, antibacterial performance, or metal-like behavior—areas explored by EPS during Innovation Week. In sustainability, bio-based plastics, second-life materials, and high-performance polymers with lower environmental impact can be integrated without compromising quality or functionality.

Combined analysis and simulations allow control of wall thicknesses, draft angles and potential molding defects. EPS’s approch, supported by its internal design office, quality department, and the close proximity between mold shop and molding department ensures continuous verification and communication throughout the process. This optimizes project time and resources.

Why choose a multi-cavity tooling or a single-cavity tooling?

Cost is not the only factor to be considered. EPS’s technical team recommends the most efficient solution based on the part requirements, production needs and investment conditions.

Key aspects in designing a plastic part include:

• dimensions, thicknesses, and sink marks
• movements and undercuts
• weld lines and warpage
• injection points and plastic material

Material selection must consider shrinkage and characteristics that influence steel choice for the mold. These factors determine acceptable tolerances and molding defects.

What influences the optimization of the molding cycle?

Cycle time of one injection molded part depends on design, mold manufacture choices and process parameters such as material preparation and injection molding machine settings. Automation for molding and assembly also plays a key role.

Efficiency and control in molding and assembly

The molding department integrates advanced technologies for parameter control, automation and real-time MES monitoring. Our connected production and digitalization allow us to predict, correct, and optimize each phase, reducing waste and increasing efficiency. This ensures consistent quality across batches and optimizes scrap and rework, including mechanical recycling along molding process when possible.

Assembly, either integrated at the press or in a dedicated area, completes the production cycle with tailored solutions, from inserting metal components to building complex subassemblies ready for the customer’s line.

When is bi-injection or overmolding the right choice?

Efficiency can also come from choosing a mold capable of processing two materials through bi-injection, or from overmolding plastic onto other components.

Integration across the supply chain and technical skills

The future requires collaboration, data sharing and integrated solutions.

Do you have a new project? Contact us!

EPS’s evolutionary approach to product development is a journey where technical expertise, industrial vision and sustainability come together to create solutions built for the future.