Polycarbonate (PC) Injection Molding

Recommended wall thickness is 1.5-3.5mm for PC. PC flows better than ABS but has higher shrink rates (0.5-0.7%). Thin walls risk brittleness; thick walls cause sink marks. Our DFM optimizes for your specific geometry.

PC offers 30x higher impact strength than acrylic and better heat resistance (138°C vs 100°C HDT). Acrylic provides better optical clarity (92% vs 89%) and is more scratch-resistant. PC is better for safety-critical applications; acrylic for displays and lenses.

Yes, we offer SPI A-2 polished molds for optical applications. For lens-quality parts, we use specialized optical grade PC with 89-91% transmission and less than 1% haze. Post-mold polishing and anti-reflective coating options available.

PC is hygroscopic and requires drying at 120°C for 4-6 hours before molding. Moisture content must be below 0.02%. Wet PC causes splay, bubbles, and degraded impact strength. We maintain strict drying protocols and moisture verification.

We source from top suppliers: Bayer (Makrolon), SABIC (Lexan), LG Chem (Lucem), and Teijin (Panlite). All grades available with full traceability and lot-specific data sheets. Medical and optical grades from certified suppliers.

Prototype molds: 7-15 days. Production molds: 4-6 weeks (due to tighter tolerances). Production parts: 2-3 weeks. Optical molds require additional polishing time (5-7 days). Rush services available with premium pricing.

Yes, we offer custom color matching using masterbatch from major suppliers. Clear, transparent tints, and opaque colors available. We match Pantone, RAL, or your sample. Small minimums for prototype colors, volume pricing for production.

Parts meet specs or we replace free. 99.7% first-pass yield backed by material certification, process SPC, and CMM verification. Optical parts undergo light transmission and haze testing. Full PPAP support for automotive.

15+ years polycarbonate expertise, optical-grade capabilities, ISO 13485 medical certification, and 99.7% first-pass yield. We offer competitive pricing, fast optical tooling, and single-source responsibility for complex transparent parts.

Medical devices (ISO 13485), safety equipment (ANSI Z87.1), electronics (optical lenses), automotive (light covers), industrial (machine guards), and consumer products. From startups to Fortune 500, 1 unit to 10M+.

Full lot traceability from raw material to finished part. Each batch provides supplier COA, manufacturing date, and quality data. Barcode tracking through production. Available for medical (MDR compliance) and automotive (PPAP) requirements.

Yes, we offer multi-year supply agreements with fixed pricing, dedicated inventory (Kanban), and mold ownership options. Stable supply chain with dual-source material strategy ensures uninterrupted production for your programs.

We achieve tolerances up to ±0.005mm on critical features using 5-axis CNC and EDM processing. Our DFM analysis helps optimize designs for manufacturability.

Yes, comprehensive mold flow analysis is included free with every project. We simulate filling patterns, identify potential defects, and optimize gate locations.

We offer ABS, PC, POM, Nylon, PP, and engineering resins. For high-stress parts, we recommend glass-filled or carbon-filled polymers with reinforced fillers.

No minimums! We support startups and small businesses with orders from 1 piece to millions. Volume discounts available for larger orders.

Prototype molds in 7-15 days. Production parts in 2-3 weeks after mold approval. Express services available for urgent projects.

Yes! Our pricing scales with volume. Contact us for a customized quote. We beat OEM pricing by 20-40% while maintaining premium quality.

15+ years experience, ISO 9001 certified, zero-defect culture, 24-hour quote response, and a dedicated team committed to your success.

Statistical process control, incoming material inspection, in-process checks, and final QC with CMM verification. Full traceability from raw material to finished goods.

Consumer electronics, automotive interiors, industrial equipment, medical devices, packaging, and more. We specialize in startups and growing businesses.