High Volume Manufacturing

High-volume manufacturing produces parts in quantities of 10,000 to over 1,000,000 units per year. Production tooling (typically hardened steel injection molds, die casting dies, or multi-cavity molds) is designed for durability and cycle time efficiency.

Per-unit cost reduces significantly at this volume tier through tooling amortisation and optimised cycle times. Consistent quality across every batch is maintained through in-process monitoring and batch inspection.

What Sets Us Apart

Engineering-Led Manufacturing

• Hardened steel tooling — rated to 500,000-1,000,000 shots for long-term programs.
• Multiple processes in-house — injection molding, die casting, blow molding, compression molding, and LSR.
• In-line quality control — dimensional monitoring on critical production dimensions.
• PPAP documentation — available for automotive customers and regulated industries.

Our High Manufacturing Capabilities

• Plastic Injection Molding — Multi-cavity hardened steel tooling for thermoplastic parts at volume. Cycle times of 10-60 seconds per shot. Suitable for housings, brackets, connectors, and structural components in PE, PP, ABS, PC, Nylon, and engineering plastics.
• Blow Molding — Continuous extrusion blow molding for hollow plastic forms at volume. Suitable for bottles, containers, and fluid reservoirs in HDPE, PP, and PET.
• Compression Molding — Multi-cavity hydraulic press compression for rubber and thermoset parts at volume. Suitable for seals, gaskets, and BMC electrical components at 50,000+ pieces per year.
• Liquid Silicone Rubber Molding — Automated LSR injection molding with multi-cavity tooling. Suitable for medical-grade and consumer silicone parts at 50,000+ units per year.
• CNC Machining — Multi-spindle CNC production for machined metal or plastic parts at volume. Suitable for components requiring dimensional tolerances that molding cannot achieve.
• Pressure Die Casting — Aluminium and zinc die casting for high-volume metal parts. Suitable for automotive components, electronics housings, and structural metal parts requiring complex geometry.

Our Process

1. DFM Review — Design for manufacturability assessment on production design files.
2. Production Tooling — Steel molds or dies fabricated and first-article trials run (T1, T2).
3. Pilot Production — Initial production batch produced with full dimensional inspection report.
4. Customer Approval — PPAP or first-article inspection report submitted and signed off.
5. Mass Production — Ongoing production with scheduled batch inspection and SPC monitoring.
6. Program Support — Tooling maintenance, engineering changes, and supply management throughout program life.

Materials

Material specifications depend on the selected production process. Full material tables are available on the Plastic Injection Molding, Die Casting, Blow Molding, Compression Molding and LSR Molding service pages.

The Output

• Volume range: 10,000-1,000,000+ parts per year
• Production tooling life: 500,000-1,000,000+ shots (hardened steel)
• Tooling lead time: 4-6 weeks (injection mold); 3-5 weeks (die casting die)
• Production batch lead time: 10-20 days after tooling approval
• Quality: ISO 9001:2015, full batch records, PPAP documentation available

Industries We Serve

• Automotive
• Consumer Electronics
• Medical
• Industrial Equipment
• Consumer Products