Injection Moulding and Tooling for Serial Production
Precision injection moulds and production-ready plastic components—from manufacturability review and mould trials to reliable serial production.
Gelecta coordinates mould design and manufacturing, injection-moulded component production, finishing, inspection and logistics through an audited supplier network. With more than 1,000 injection moulds delivered and over 25 years of international manufacturing experience, we help customers move demanding plastic components into production with controlled quality, cost and schedule.
You can order the mould for production at your own facility or manufacturing partner, or let Gelecta manage both the tooling and ongoing component supply. In either model, the mould belongs to the customer.
1,000+ injection moulds delivered
25+ years of international manufacturing experience
Customer-owned tooling
ISO 9001 and ISO 14001 certified management systems
A complete route from customer CAD data to serial production
Injection moulding is most effective when the component, mould and production process are developed as one system. Decisions about material, wall thickness, draft, parting lines, gates, ejection and cooling affect not only whether the part can be moulded, but also its appearance, dimensional stability, cycle time and unit cost.
Gelecta supports the complete route:
- design-for-manufacturing review and material evaluation
- mould concept, design and manufacturing
- Moldflow analysis and technical risk review where required
- mould trials, measurement and sample approval
- process optimisation and preparation for serial production
- injection-moulded component production
- inserts, painting, printing, laser marking and other finishing
- sub-assembly, customer-specific packaging and logistics
- quality assurance and production follow-up throughout the product lifecycle.
Early technical review helps avoid expensive tool modifications, improve part consistency and establish a cost-effective production solution before steel is cut.
Two flexible operating models
Mould manufacturing for your selected production site
Moulds and serial components from one partner
The mould always belongs to the customer
Through its selected specialist tooling partner, Gelecta can coordinate the design and manufacture of the injection mould and deliver the validated tool to the customer or a nominated manufacturing partner in Europe. This model is suitable when the customer already has an established production location but needs a technically capable and cost-effective tooling solution.
The project can include DFM review, mould design, Moldflow analysis, mould trials, sample parts, dimensional inspection and the documentation agreed for tool transfer and production start-up.
Gelecta can also manage the complete programme from mould manufacturing to recurring component production. We coordinate the production partner, mould maintenance, purchasing, quality assurance, finishing and logistics so the customer receives approved components according to the agreed delivery plan.
Components can be delivered as moulded parts or with the secondary operations and sub-assembly required for the customer’s own production.
Whichever operating model is selected, the mould is customer-owned. This provides a clear basis for long-term production and preserves the option to transfer the tool if the manufacturing strategy changes.
DFM and mould engineering before tooling investment
A successful injection-moulding project begins before mould manufacturing. We review the customer-supplied CAD data, drawings and production requirements to identify technical risks and cost drivers while changes can still be made efficiently. The customer retains responsibility for the component design and approves any proposed design revisions before they are implemented.
The review may cover:
- material selection, shrinkage and expected operating environment
- nominal and varying wall thicknesses
- draft angles and ejection
- ribs, bosses, snap fits and other functional features
- undercuts, side actions and tool complexity
- parting-line and gate locations
- weld lines, air traps and filling behaviour
- cooling, deformation and dimensional stability
- critical dimensions, tolerances and assembly interfaces
- cosmetic surfaces, texture and permissible process marks
- inserts, overmoulded features and secondary operations
- cavity count, expected annual volume and unit-cost targets.
Moldflow analysis can be used to evaluate filling, pressure, cooling and potential risk areas before the mould is manufactured. The objective is not only to make a part that fills the cavity, but to create a stable and economical process that repeatedly produces acceptable components.
Gelecta quotations include DFM and Moldflow reports at no additional cost.
Materials and performance requirements
The customer may specify an exact polymer and grade, or suitable alternatives can be evaluated with the selected manufacturing partner. Material selection is based on the component’s mechanical performance, appearance, operating environment, dimensional requirements and applicable compliance requirements.
Common options include ABS, PC/ABS, PC, PP, PA, POM, PBT and flexible TPE or TPU materials, as well as glass-fibre-reinforced, flame-retardant, UV-resistant and other modified grades. Material availability, processing requirements and documentation are confirmed for each project.
Technical and appearance-critical plastic components
Gelecta supports injection-moulded components whose function, fit and finished appearance must all be controlled. Typical projects include:
- equipment, electronics and instrument housings
- medical and health-technology device components
- watertight and protective enclosures
- optical and lighting components
- covers, panels, handles and user-interface parts
- brackets, gears and other functional technical components
- components with threaded or moulded-in inserts
- multi-material or overmoulded parts
- visible parts with defined colour, texture and gloss
Component feasibility and the production route are evaluated from the CAD model, material requirements, annual and lifetime volume, tolerance requirements, finish and intended use.
Quality assurance from mould trial to repeat production
Quality requirements should be defined before the mould is manufactured and carried through to serial production. Depending on the project, the control plan can include:
- approval of the mould design and technical documentation
- material certificates and compliance documentation
- first-article dimensional inspection
- measurement reports for critical dimensions
- visual reference samples and cosmetic acceptance criteria
- colour, gloss and texture control
- functional, fit or leak testing
- process monitoring and batch-level inspection
- supplier audits and production follow-up
- project-specific reporting and traceability requirements.
Gelecta’s own sourcing manager in China works close to the supplier network and supports production follow-up, communication and local quality assurance. Customers can also participate in supplier visits or audits when required.
We do not publish one general tolerance for all injection-moulded components. Achievable accuracy depends on the material, part size, geometry, mould construction, process stability and measurement method. Critical tolerances are reviewed against the CAD model and drawing before tooling.
Finished components ready for your production
The injection-moulding cycle is often only one part of the required delivery. Gelecta can coordinate secondary operations and related components so parts arrive closer to their final form.
Project-specific services can include:
- moulded-in or post-installed threaded inserts
- painting and protective or decorative coatings
- pad printing, screen printing and laser marking
- bonding and welding of plastic components
- purchased parts and components made with other technologies
- functional testing and inspection
- sub-assembly
- customer-specific labelling and packaging
Combining these operations into one managed delivery reduces the number of suppliers, transport stages and incoming production tasks the customer must coordinate.
More than 500 injection-moulding projects for Laukamo
Complex watertight enclosures for Aplicom
Frequently asked questions
Who owns the injection mould?
The customer owns the mould. Gelecta can keep it at the agreed manufacturing site for component production or arrange delivery to the customer or another nominated production partner.
Can Gelecta supply only the mould?
Yes. Based on the customer’s component design, we can manage the DFM review and coordinate mould design, manufacturing, trials, sample inspection and tool delivery for production at the customer’s selected facility. Alternatively, we can manage both the mould and recurring serial component supply.
When is injection moulding the right manufacturing method?
Injection moulding is typically suitable when repeatable production, final thermoplastic materials and a low unit cost at recurring volumes justify the tooling investment. The decision should consider annual and lifetime demand, part complexity, material, quality requirements and the expected product lifecycle—not quantity alone.
What information is needed for a mould quotation?
The most useful starting point is a 3D CAD model together with a dimensional drawing, material requirements, quantity forecasts, cosmetic requirements, finishing operations and the target schedule. Critical tolerances and quality documentation should be identified as early as possible.
Can you help optimise an existing design for injection moulding?
We do not provide product or component design. However, the DFM review can identify issues related to wall thickness, draft, undercuts, ejection, gate location, shrinkage, deformation and tool complexity. Any proposed changes are submitted to the customer, who retains design responsibility and approves revisions before mould manufacturing.
Do you provide Moldflow analysis?
Yes, Moldflow analysis can be included to evaluate material flow, pressure, cooling, weld lines, air traps and potential deformation before the mould is manufactured. The scope is defined according to the component and project risks.
What materials can be injection moulded?
The available range includes common thermoplastics and more demanding engineering materials. The specific grade is selected according to mechanical performance, temperature, chemicals, appearance, compliance requirements and availability.
Can parts be supplied painted, marked or assembled?
Yes. Depending on the project, injection-moulded parts can be supplied with inserts, painting, coatings, printing, laser marking, bonding, testing, sub-assembly and customer-specific packaging.
How are mould trials and samples approved?
Trial parts are evaluated against the agreed dimensional, visual and functional requirements. Customers can participate in the mould trial remotely through Gelecta’s VTA service. When required, physical samples are also sent to the customer for internal inspection and testing.
Serial production begins only after the samples, inspection results and other agreed documentation have been reviewed and approved against the project-specific acceptance criteria.
How long does an injection-moulding project take?
Following approval of the DFM review, the typical lead time to first-off-tool (FOT) samples is around 60 calendar days. This includes mould design, manufacturing and the first mould trial. The lead time may vary depending on the component geometry, mould construction, cavity count and material.
The total time to serial production also depends on the trial results, any required modifications, inspection documentation and finishing requirements. We confirm the tooling and production schedule after reviewing the customer’s CAD data and project requirements.
Can the mould be transferred to production in Europe?
Yes. Gelecta can manufacture and validate the mould for delivery to the customer or a nominated European manufacturing partner. Moulds intended for production in Europe are equipped with standard mould components readily available in the European market, such as HASCO standard parts. This simplifies future maintenance and the sourcing of replacement components.
The requirements of the destination machine, applicable mould standards, interfaces and transfer documentation are agreed at the beginning of the project.