With over 23 years of experience in high-precision mold making and plastic injection, we specialize in crafting advanced thin wall injection molds that meet the rigorous demands of high-volume, lightweight plastic parts.

What Are Thin Wall Plastic Injection Molds?

Thin wall plastic injection molds are engineered to produce components with reduced wall thickness — typically less than 0.080 inches. These parts are commonly used in disposable food containers, storage bins, and large pails like 5-gallon buckets.

By minimizing wall thickness:

• Product weight is reduced
• Cycle times are significantly shorter
• Material costs decrease
• Production efficiency increases

But with these advantages come challenges: achieving tight tolerances and maintaining consistent quality across thousands — or millions — of parts requires expert mold design and deep knowledge of plastic behavior and shrinkage.

Key Features of Thin Wall Mold Design

Producing successful thin wall molds isn’t just about making thinner parts — it requires thoughtful design, robust materials, and precision engineering. Here are some essential mold design considerations:

• Use steel harder than P20 to resist wear and erosion in high-cavitation tools.
• Include interlocks to prevent misalignment or flexing during high-pressure cycles.
• Design telescoping cores that insert into the cavity to reduce core shifting and breakage.
• Integrate preloaded support plates and heavy-duty support pillars for extra strength.
• Use multiple large ejector pins to reduce pin pushing force and aid part ejection.
• Apply a #2 diamond polish to prevent sticking, or consider surface plating.
• Ensure proper venting to prevent trapped gases and improve part finish.
• Leverage externally heated manifolds to reduce pressure drops in runner systems.

Even if your part has challenging geometry, don’t compromise your design — talk to us first. Our team is ready to develop the mold solution you need.

Real-World Success: Disposable Food Container Project

A client in the food packaging industry needed to boost capacity due to rising sales. Their goal: a 12-cavity mold capable of fast cycle times while maintaining consistent, thin wall part quality.

We successfully delivered:

• Part Height: 2.015”
• Volume: 0.439 in³
• Material: Polypropylene (PP)
• Shrink: 0.018”
• Stroke: 2.000”
• Mold Weight: 7,200 lbs
• External Dimensions: 23″ (L) × 33″ (W) × 39″ (H)

Our innovative mold design provided the speed, reliability, and repeatability the client required — without compromising on part quality.

Ready to Discuss Your Thin Wall Project?

Whether you’re developing a new product or looking to improve manufacturing efficiency, our team of experts is here to help. Challenge us with your thin wall injection molding needs — and experience the difference precision makes.

📩 Contact Us Today