The different custom moulding techniques and services we offer are summarised below, where you can learn more about individual manufacturing options. 

• Rubber Compression Moulding - This form of moulding uses heat and pressure to form the product's final shape. This method uses a heated cavity and vertical press mechanism to effectively construct and maintain the required tooling. It is known for wasting less material than injection moulding due to the specialist tooling used. This technique produces an aesthetically and functionally superior surface finish. It is the go-to technique for large, flat and curved components. This form of moulding is used to manufacture electronics, medical components (such as respirator masks), cookware, phone cases and much more.    

• Polyurethane Foam Moulding - Polyurethane moulding is a technique used in wide-scale manuacturing. Polyurethane is dispensed into heated moulds, heat cured and then trimmed or machined into required shape. This process suits both high and low volume production, while also allowing metal parts to be incorparated into the product and is flame resistant in some materials used. For example, higher tempreture grades can be used for -30 degree to +80 degrees tempretures which gives it an advantage against other forms of moulding. Some applications include scrapers, castors, gaskets, seals and isolators.

• Rotational Moulding - This technique involves a heated mold which is filled with a charge or shot weight of material. It is a thermoplastic moulding process effectively used for production volumes of less than 3,000 annually. It is mostly used for parts that require high-quality finishes, uniform wall thicknesses, and high stability. Advantages of this technique include low-cost tooling, consistent wall thicknesses of the product, high strength, stability and fine details/appearance. There are disadvantages, such as high labour costs, high cost of material and options, as well as low repeatability. It is used in products such as containers, tanks, kayaks and coolers.

• Dip Moulding - This moulding technique is similar to candle making in its process. Heated metal moulds are dipped in a tank of liquid material. The moulds are extracted and then put through a baking process to cure the material before the product is stripped from the material. It is dipped multiple times to build up layers of material. The process is very cost-effective and time-efficient. It is ideal for mass-production and is cextremly precise while also able to be developed in different materials and colours. Some applications include grips for tools, caps, and sleeves.

• Injection Moulding - The process of injection moulding works by injecting molten materials into a mould. It is most commonly used with thermoplastics and thermosetting polymers. The injection process requires careful design, including the shape and features of the part, the materials for the part and the mould. This requires meticulous consideration when using this technique. Entry cost for injection moulding is high, plus can be expensive to create individual parts. However, in high consistencies can be very low-cost once tooling is operational. Part reliability and consistency in quality management is a big advantage for this technique. Injection moulding can suffer when trying to create large continuous pieces of a material. Applications for this technique include chairs, toys, storage containers, mechanical parts and automotive components.

• Over Moulding - Overmoulding is the process of adding an additional layer of material over an already existing piece or part. For example, the shaft of a screwdriver is overlayed with plastic over the metal drive to form the handle. Hot molten plastic fills the area around the inserted part or material, assembling the final product. Some advantages of this technique eliminates the neeed for secondary assembling operations, while also allowing for a part to be waterproofed and shock resistantant. Parts produced using this technique are tough, lightweight and chemical resistant. The process is used in many industries and can be used for electronic PCBs, tools, cable assemblies, connectors, and fasteners. Materials include ABS, LCP, PBT, Nylon, Polycarbonate, PPS, Acrylic, Polyproplene, PPA and many more.

To help with customer peace of mind, here in the Technical Department of Vital Parts we can design and develop your prototypes using many different applications and trial phases.

Why use Vital Parts printing service?

• Large range of materials available and colour options
• Rapid quote turnaround
• Component design support for your product
• Same day prototype prints 
• Quick delivery times
• Free no obligation quote for tooling and moulded parts after prototype validation

Materials: 

PLA,ABS,HIPS,PC,TPU,TPE,PTG,ASA,PP,Nylon,Glass fibre Grades, Carbon Fibre Infused Grades, Metal Filled Grades,Woodfill and more..

Colours: 

Black and white/Natural/Enquire for more colours

Max. Part Size: 250mm x 250mm x 250mm

We also offer a service for colour variations of anything stainless steel. Black oxide conversion is a service and solution we can provide to ensure colour-coding of screws, nuts and bolts. Or, just about anything stainless steel. 

So How Does It Work?

Black oxide is a conversion coating process between the oxidizing salts used and the material. The end result is an incredibly thin layer of magnetite added to the ferrous material (metal). The chemicals used include Sodium Hydroxide (lye) and Sodium Nitrate (Chile Saltpeter). Three tanks are used and parts are move into a hot bath (between 194 to 286°F) containing an alkaline detergent (lye), then water, and lastly a bath of sodium nitrate. Oil is applied while the parts are still hot which acts to seal the finish. This process is generally referred to Hot or Mild Temperature bath depending on the temperature used.

What metals can be used with black oxide?

• Steel and Alloy Steel
• Stainless Steel
• Copper (often called Ebonol C)
• Zinc (often called Ebonol Z)