Polycarbonate (PC) Injection Molding at Production Scale
Polycarbonate injection molding is the answer when a part must be clear, tough, and heat-resistant at once. Lenses, light pipes, and transparent housings lean on PC because almost nothing else matches its impact strength and clarity.
PC is unforgiving on process. It must be bone dry, gated gently, and filled at the right speed or it stress-whitens and turns brittle. The difference between a good optical part and a scrap one is entirely in drying and fill control.
What the Capability Numbers Mean for Your Program
The specifications define the envelope in which polycarbonate (pc) injection molding stays predictable. A press range of 50T - 800T covers parts from small precision features to larger functional components without splitting the program across vendors. Tolerances of ±0.02 mm describe where critical features are controlled rather than left to chance.
Mold life rated at 300,000 - 1,000,000 shots is a maintenance plan, not a sales figure. Tools are serviced by shot count so wear never surprises a shipment. Tooling lead time of 20 - 40 days reflects complexity and validation, and an annual capacity above 30,000,000 parts signals a floor built for sustained volume.
How a Program Runs
- Design for manufacturability. Geometry, gate location, and draft are reviewed so the part molds predictably and meets function.
- Material and tool selection. Resin grade and tool steel are chosen for the performance, volume, and life the program requires.
- Tool fabrication. The mold is machined, with hot-runner or multi-cavity features where the program specifies them.
- Molding and process setup. Parameters are developed and locked so fill, pack, and cooling stay inside the validated window.
- In-process verification. Critical dimensions are checked with gauges and CMM; results are recorded for traceability.
- Packaging and shipment. Parts are inspected, packed, and shipped against the agreed quality and delivery plan.
Material and Application Fit
Material grade is matched to optical or structural needs, with hard-coat options for scratch resistance. We maintain high-polish tool surfaces and verify clarity and distortion on optical parts.
Related capabilities
- Enclosures & Housings Molding
- Consumer Electronics Injection Molding
- Precision Injection Molding
- Medical Plastic Injection Molding