As we work our way through 2023, there are several trends that are shaping the injection moulding business. In this article, we will explore the Top 10 Trends in the Injection Moulding Business that are having and are expected to continue to have a significant impact on the industry in the coming years. From automation and digitization to sustainable practices and new materials, these trends play a crucial role in determining the success of injection moulding businesses in 2023 and beyond.
The first five trends paving the way to success
1. Use of Sustainable Materials: The demand for sustainable materials is driven by increasing consumer and regulatory pressure to reduce environmental impact. Companies are responding by using bio-based, recycled, and biodegradable plastics in injection moulding. For example, in 2020, Toyota developed a new biodegradable material for automotive interiors made from potato starch and other plant-based materials.
2. Smart Manufacturing: Smart manufacturing technologies such as Industry 4.0 are transforming the injection moulding industry. Automation, artificial intelligence, and predictive maintenance are being used to optimize production and reduce downtime. For example, Engel, a global injection moulding machine manufacturer, has developed an intelligent assistance system that uses machine learning algorithms to optimize process parameters in real-time.
3. 3D Printing in Tooling: 3D printing is increasingly being used for rapid prototyping and tooling. 3D printing enables faster tooling iterations and better-quality control in injection moulding. For example, in 2020, GE Additive developed a 3D-printed injection mould for a critical aircraft engine part that reduced lead time from 14 weeks to 3 days.
4. Hybrid Moulding: Hybrid moulding, which combines two or more moulding techniques, is being used to produce complex geometries and multi-material parts. Hybrid moulding reduces assembly costs and improves part performance. For example, in 2020, the medical device company BD developed a hybrid moulding process that combined injection moulding and blow moulding to produce a multi-layer blood collection tube with improved stability and functionality.
5. Micro-Moulding: The demand for miniaturization is driving the growth of micro-moulding. Micro-moulding enables the production of small, complex, and precise parts for various industries, including medical devices, electronics, and automotive. For example, in 2020, Miniature Precision Components (MPC) developed a micro-moulding process that enabled the production of high-precision medical components with dimensions as small as 0,127 mm (0.005 inches).
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6. Multi-Cavity Moulding: Multi-cavity moulding is being used to produce high-volume parts at a lower cost. The use of multi-cavity moulds reduces cycle time, increases productivity, and improves part consistency. For example, in 2020, the packaging company Berry Global developed a multi-cavity mould that enabled the production of 60-cavity preforms for PET bottles.
7. Injection Moulding Simulation: Simulation software is being used to optimize mould design, reduce cycle time, and improve part quality. For example, in 2020, the simulation software company Moldex3D developed a new simulation tool that enables the prediction of warpage in injection-moulded parts, enabling mould designers to optimize part design and reduce scrap.
8. Advanced Materials: The use of advanced materials such as composites, thermoplastics, and thermosets is increasing in injection moulding. Advanced materials offer better strength, stiffness, and durability, enabling the production of lightweight and high-performance parts. For example, in 2020, Solvay introduced a new composite material called NovaSpire, which enables the production of lightweight and high-strength parts for aerospace and other industries.
9. Medical Injection Moulding: The demand for medical injection moulding is growing. Medical injection moulding enables the production of high-precision, sterile, and biocompatible parts for medical devices and implants. For example, in 2020, Phillips-Medisize, a global medical injection moulding company, developed a new medical device called FlexConnector, which enables the connection of multiple medical devices with a single port.
10. Globalization: The globalization of injection moulding is accelerating. Injection moulders are increasingly looking to expand their operations globally, tap into new markets and reduce costs. For example, in 2020, the global injection moulding company, Flex Ltd, announced plans to open a new manufacturing facility in Malaysia, to meet growing demand in the Asia-Pacific region.
Overall, these Top 10 trends in the injection moulding business in 2023 and 2024 are driven by the need to improve efficiency, reduce costs, and meet the demands of a changing market while ensuring a greener, more environmentally friendly future. Companies that adopt these trends will be able to stay competitive and adapt to changing market conditions.
Did you know that companies that align with global trends are more likely to give you an additional advantage and value? We are putting in a continuous effort to stay at the forefront of current and emerging trends! Get in touch to see, how we can help you either develop, produce, bring to market or all of the above.
