Injection Moulding
Injection Moulding with Borough
Injection moulding has always been a significant part of the services we offer here at Borough. In recent years our capabilities have become increasingly important to our customers, as they seek locally sourced, high-quality components, from manufacturers they can rely on to deliver.
Whether the injection moulded components we produce are to be chrome-plated or not, we follow the same high-quality precision moulding process. We utilise the latest moulding technology from the likes of Sandretto, which allows us to produce smaller parts to tighter tolerances to ensure we continually improve the quality of the injection moulded components we supply.
Our newest ENGEL injection moulding machine, with a 300kN clamping force, employs tie-bar-less technology that allows us to effectively mould larger components on a smaller machine. This saves energy whilst also ensuring we can swap tools more quickly and efficiently.
To help minimise problems in the injection moulding process, we will project manage the design of tools, especially for components that are to be chrome-plated, which requires a slightly different approach to tool design.
Working closely with tool manufacturers, we take the product through all the stages of design, through to the production part approval process (PPAP) and final production of high-quality parts. It is our constant attention to detail and determination to improve that sets Borough apart.
Final quality of the finished product depends on the condition of the moulding. This is why we continue to invest in the future and train all members of the moulding team in the process and delivery of high-quality components.
We continually seek ways to improve our injection moulding service and this has been paramount since we achieved first tier supply status and QS 9000, which closely examines the quality, fit and function of everything we do.
To achieve the best quality plated injection moulded components, we recommend the designer, tool maker and team here at Borough liaise from the conception of the product, long before tools are designed. It is also useful, for designers to have a basic guide to help them understand the special design requirements of components specifically injection moulded for chrome plating.
What is Injection Moulding?
Injection moulding is a widely-used manufacturing process designed to produce components and products by injecting a molten material into a suitable mould. It is a highly versatile process, capable of creating complex and precise components for a variety of industries, from automotive manufacturing to consumer goods.
Injection moulding involves several distinct steps that ensure the production of parts not only achieves the highest quality final product, but that this quality of finish is consistent:
Material preparation – the process begins with raw materials, often in the form of plastic pellets or granules. These materials are selected based on the required properties of the final product (e.g., durability, flexibility, ability to be plated or resistance to heat).
Melting – the raw material is fed into a heated barrel where it is melted to a liquid state. The temperature is carefully controlled to ensure proper flow and material integrity.
Injection – the molten material is then forced under high pressure into a mould cavity, which is typically made of steel or aluminium. This ‘moulding tool’, is precision-engineered to match the required shape of the final part.
Cooling – once the material fills the mould, it begins to cool and solidify. The cooling time which is managed closely is crucial and depends on the material properties, part thickness and design of the mould.
Ejection – after the material has solidified, the mould opens, and the part is ejected using ejector pins or mechanisms such as robotic vacuum assisted arms that lift part clear of the press. The mould then closes, and the cycle begins again.

Want to Find Out More About Injection Moulding?
If you have a project that would benefit from the quality, durability and weight-saving offered by injection moulded plastic, get in touch to see how we can make your design a reality.
Key features of injection moulding
Injection moulding excels at producing parts with tight tolerances and intricate geometries. This precision makes it ideal for creating components used in industries such as automotive, aerospace and medical device manufacture.
The process is highly efficient, especially for large-scale production. Depending on the scale of the component to be moulded the creation of the tool is one of the most expensive aspects of the process and time has to be spent at this stage to ensure it is as good as it can be – changes to tolls after they have been created can be expensive and tine-consuming.
However, once the moulding tool has been created, production cycles are quick and allow for the fast output of high-quality components, with each one as good as the first.
A wide variety of materials can be used for the injection moulding process and for some manufacturers such as Borough, speciality materials like ABS which is used for chrome plating after moulding are used.
A second material, which cannot be chrome plated, can be combined in the same injection moulding process to create components with un-plated areas such as fixing tabs, for more specialist applications. This is known as two-shot moulding.
The real strength of the injection moulding process is that it ensures consistent quality across thousands or even millions of parts, making it suitable for mass production. Manufacturers can rely on each component fitting their quality and specification parameters, time after time, reducing the need for hand assembly of final systems.
Modern injection moulding systems are designed to minimise waste by reusing material from excess sprues, runners, or other remnants. An approach that also keeps cost as low as possible in a competitive global market where cost to some end-users is more important than sustainability.
Advantages of Injection Moulding
There are numerous advantages of the injection moulding process to achieve high-quality components of a consistent standard:
Cost-effectiveness for high volumes: The initial cost of creating the moulding tool can be high, but its cost spread across components decreases significantly with larger production runs.
Scalability: Injection moulding accommodates both small and large production runs, making it ideal for prototyping and mass production alike.
Design flexibility: Complex shapes, undercuts, and detailed textures can be incorporated into mould designs. Two-shot moulding can be used for components that need to be plated, but require parts left un-plated for fitments.
Durability: The process supports high-performance materials, resulting in parts that withstand harsh conditions, high stress, and temperature variations, which can easily be electroplated.
Automation-friendly: The process is often automated, ensuring consistent quality and reducing production costs.
Injection moulding is a cornerstone of modern manufacturing, combining precision, efficiency, and versatility. By leveraging modern technology and a deep understanding of materials, manufacturers such as Borough can produce components that meet stringent quality standards, whether the finished components are to be used un-plated or electroplated.
Here you can read about the advantages of using a single source for injection moulding and electroplating of components.
Frequently Asked Questions
Can ABS be injection moulded?
Yes, ABS (Acrylonitrile Butadiene Styrene) is one of the most commonly used materials for injection moulding, thanks to its versatility, strength, and excellent processability, which make it an ideal choice for numerous diverse applications.
ABS softens when heated and solidifies upon cooling, making it well-suited for injection moulding. It also offers a good balance of toughness, impact resistance, and rigidity, whilst being easy to process. It flows well during moulding, making it suitable for use with complex tools needed to produce components with intricate details.
ABS can also be coloured, textured, or blended with additives to enhance properties like UV resistance or flame retardancy. In the hands of experts like Borough, it is the ideal substrate for high quality mouldings destined to be electroplated, typically with bright or satin finish chrome used in automotive applications.
Can polypropylene be injection moulded?
Yes, polypropylene (PP) can be injection moulded, and it is one of the most commonly used materials for this process due to its versatility and excellent properties. Polypropylene is a thermoplastic polymer, which means it softens when heated and can be reshaped, making it ideal for injection moulding.
Thermal Stability: Polypropylene has a high melting point (around 130-170°C), making it easy to process during injection moulding.
Good Flow Characteristics: It flows well when molten, allowing for the production of intricate and detailed parts.
Chemical Resistance: It is resistant to many chemicals, including acids, bases, and organic solvents, making it ideal for a wide range of applications.
Toughness and Flexibility: Polypropylene combines rigidity with impact resistance and flexibility, making it suitable for durable and functional products.
Low Density: Its lightweight nature makes it a cost-effective material for large-scale manufacturing.
How long does injection moulding take?
The time required for injection moulding depends on several factors, including the complexity of the part, the material used and the specific moulding conditions. However, the injection moulding cycle typically follows these stages:
Mould Clamping (1–2 seconds): The mould closes securely to prepare for material injection.
Injection of Material (2–60 seconds): Molten plastic is injected into the mould cavity under high pressure. The time this takes depends on the part’s size, complexity and material flow properties. For smaller parts, this can be a few seconds, but for larger parts, it can take up to a minute.
Cooling Time (20–120 seconds): The plastic solidifies in the mould. Cooling time is often the longest part of the cycle and depends on factors such as wall thickness, material properties (e.g., ABS cools faster than some engineering plastics), mould design and cooling system efficiency.
Mould Opening and Ejection (2–5 seconds): The mould opens, and the part is ejected. Ejection times are generally very short.
Is injection moulding environmentally friendly?
Injection moulding has both environmental challenges and opportunities. While the process involves energy use and often relies on non-biodegradable plastics, its efficiency, recyclability, and adaptability to sustainable materials make it a viable option for eco-friendly manufacturing.
Adopting greener practices and re-using waste materials, allows manufacturers to significantly reduce the environmental impact of injection moulding.
What are the advantages and disadvantages of injection moulding?
Injection moulding is a powerful manufacturing method with significant benefits for high-volume, complex and precise components. However, its high upfront costs and longer lead times make it less suitable for low-volume or rapidly changing designs.
Understanding these trade-offs helps manufacturers choose whether injection moulding is the right solution for their needs. Choosing a single source for the injection moulding and electroplating of parts makes good economic and logistical sense.
Advantages
High production efficiency
Versatile material options
Ability to produce complex and precise parts
Cost-effective for large production runs
Reduced waste with recyclable materials
Disadvantages
High initial tooling and setup costs
Long lead times for mould tool development
Material and size limitations
Expensive for low-volume production
Potential environmental concerns
Get in Touch
If you’d like to learn more about our injection moulding or chrome plating services, then please get in touch and our in-house team will talk you through the steps to injection moulded perfection.