Injection Molding

Complete end-to-end solution from mold design, mold flow analysis, DFM, VAVE, FMEA, multi-cavitation mold fabrication, testing and commission for mass production of plastic injection molding

Injection Molding Applications

Plastic injection molding has extensive applications across various industries.

Healthcare / Medical device injection molding

Surgical Devices, Hearing Aids, Glucose Infusion Meters, Syringes, and Contact Lens Case etc. (certified to ISO 13485).

The process of healthcare / medical injection molding ensures the production of high-quality and biocompatible medical components that comply with stringent regulatory standards. Healthcare / Medical device injection molding plays a critical role in enabling advancements in healthcare by delivering safe, reliable, and cost-effective solutions for various medical applications.

Automotive industry

Advanced Driver Assistance Systems (ADAS) which include automotive sensors and components, navigation systems, automotive LiDAR, forward-facing Camera, and fuel injection connectors, ECU housings, and EV applications etc. (certified to IATF 16949).

The automotive industry demands precision, durability, and aesthetic appeal, all of which can be achieved through injection molding. This process allows for the creation of complex shapes and intricate designs, ensuring precise fit and function of the components produced. It enables consistently zero-defect-quality, high volume production parts while reducing costs and ensuring timely delivery. The use of different materials, such as reinforced plastics, enhances the strength and durability of automotive parts, meeting rigorous performance requirements.

The versatility and wide-ranging applications of plastic injection molding make it an indispensable manufacturing process for numerous industries seeking high-quality, cost-effective, and customized plastic parts.

Engineering Services

  1. Rapid Prototyping

  2. 3D Visualization of Solidification Results

  3. Validation Assembly of New Mold Designs

  4. Process Simulation

  5. Tooling Design

  6. Manufacturing Simulation

  7. Metallurgical Testing

  8. Dimensional Inspections

Value-added solutions – In-house Polymer Solutions

Beyonics utilizes in-house polymer solutions to provide a wide range of bespoke polymer products made to customer design specification. Driven by Environment care, quality control, supply stability & value creation, Beyonics engineer High Performance Thermoplastics Compound for Total Solution, Quality, Supply & Cost in mind.

Injection Molding Machines

  • Equipped with 15 – 1,600 ton injection machines;
  • Vertical molding machines (Up to 1 Cav/3 Core);
  • Horizontal molding machines (High speed) for 2K molding, glass insert molding, Teflon molding etc.;
  • Able to handle resins from common PP, ABS, PC, PCABS, PA etc. to more complex engineering plastics for example PPS up to 65%GF, PEI, PEEK, PFA etc.;
  • Fully and semi-automated insert molding with visual checking integration.

Secondary / Additional Process

  • Heat-staking, ultrasonic welding, laser-marking, connector assembly, glue dispensing and gasket-dispensing capabilities, reagent management (storage/filling).

Quality Assurance

  • Full Test Lab that diagnoses cleanliness, contamination of processes, parts, and systems;
  • Quality Assurance Laboratory with full-fledged equipment such as smart-scope, CMM, and different testers.

Certifications / Standards for Manufacturing and Validation

  • ISO 45001:2018;
  • ISO 9001: 2008;
  • ISO 13485;
  • IATF 16949;
  • Clean Room 8;
  • FDA audited production site.

Locations Featuring Plastic Injection Molding

Bio-burdened clean room for Class 3 medical devices and high precision insert molding for automotive components.

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