ABS Injection Molding Services

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Precision ABS Molding Solutions by KingStar Mold

At KingStar Mold, we deliver precision with expert ABS injection molding services. From sleek gadgets to durable household items, we perfect every part, ensuring lasting quality. Trust us to bring your designs to life with accuracy and care.

Versatile Applications of ABS Injection Molding Across Industries

ABS plastic’s durability, strength, and aesthetic appeal make it ideal for a wide range of industrial applications.

Consumer Electronics

Smartphone housings
Laptop casings
TV bezels
Remote controls
Keyboards
Headphone ear cups
Chargers
Speaker enclosures

Appliances

Washing machine panels
Refrigerator components
Microwave housings
Vacuum cleaner parts
Coffee machine bodies
Dishwashers’ outer casings
Heater fan components
Air conditioner parts

Medical Devices

Diagnostic equipment housings
Surgical instrument handles
IV pump components
Medical trays
Drug delivery devices
Ventilator parts
X-ray machine covers

EV & Automotive

Interior trim
Door handles
Dashboard panels
Lighting components
Bumper covers
Instrument clusters
Air vents
Mirror housings

ABS plastic fabrication is commonly used in both everyday products and industrial applications, with the examples above representing just a fraction of its versatility. At KingStar Mold, we have extensive expertise in ABS injection molding, including working with modified ABS materials such as PC+ABS, ABS+PA, ABS/PBT, and Flame-Retardant ABS.

ABS Injection Molding Process Step-By-Step

ABS injection molding is a systematic and precise manufacturing process. To ensure the quality of the final product, each step requires strict control of process parameters. The following is a detailed step-by-step explanation of the ABS injection molding process based on industry practice and specific data.

Step 1: Raw material pre-treatment (drying)

The moisture absorption rate of ABS resin, which is hygroscopic, usually falls between 0.2% and 0.4%. An excessively high moisture content in the plastic particles will result in a number of issues, such as higher operating costs and longer processing times. Additionally, the molded parts will become cloudy in appearance or have flaws like silver streaks(splay marks), bubbles, etc. on the surface if the moisture is not entirely eliminated.

Drying temperature: It is generally advised to dry at 80–90°C; however, it can be adjusted between 75 and 95°C depending on the seasonal humidity.
Drying duration: At least two to four hours; in humid conditions, this time may need to be increased to four to eight hours. It might even take eight to sixteen hours for complicated products with high gloss requirements.
Target moisture content: After drying, the material’s moisture content should be lowered to less than 0.05%, which is a crucial sign for avoiding surface flaws.

Step 2: Mold Preparation

The condition of the mold directly affects the filling effect and the ease of removing the product from the mold(part ejection/demolding).

Mold temperature: Usually maintained between 25°C and 70°C. In actual production, to achieve better surface finish and reduce internal stress, the mold temperature is usually maintained within a higher range of 60–80°C.
Surface treatment: Before molding, the mold cavity needs to be cleaned, and an appropriate amount of release agent can be applied as needed to facilitate ejection.
Venting: A reasonable venting groove is crucial as it can prevent burn marks or insufficient filling caused by trapped air.

Step 3: Parameter Setting and Calibration of Injection Molding Machine

Melting temperature: The processing temperature range of ABS is quite wide, typically ranging from 210°C to 280°C. The commonly recommended temperature is 245°C. For special grade products such as those with poor thermal stability (like flame-retardant ABS), the upper temperature limit needs to be appropriately reduced. It should be noted that ABS materials will undergo thermal decomposition when overheated (i.e., high temperature causes chemical bonds to break); usually, the appearance of brown or charred marks on the components indicates that the injection temperature is too high. If higher part gloss is required, the molding temperature must be maintained at a higher level without damaging the material.
Injection pressure: Usually within the range of 500 to 1000 bars (approximately 5000 to 10000 pounds per square inch). Higher injection pressure is typically needed because ABS has a higher viscosity; however, lower pressure might be more appropriate for smaller, simpler, or thicker ABS products. If the injection pressure is too low, the mold shrinkage rate will increase and the part size may exceed the tolerance range and fail to meet the design requirements; if the injection pressure is too high, the friction increases and the molded parts stick together, making demolding more difficult and raising production costs. Particular circumstances call for particular analysis.
Injection speed: It is recommended to use medium to high speed injection to ensure that the melt fills the mold cavity completely before cooling. Note that to enhance dimensional stability, the injection volume required for ABS is smaller than that for other plastics.
Holding pressure and time: After injection, a holding pressure needs to be applied to compensate for melt shrinkage. It is usually 50-70% of the injection pressure. The holding time is determined by the freezing time of the gate.
Cooling time: It depends on the wall thickness of the product and is usually between 10–60 seconds. For thick-walled parts, it may take 1-3 minutes to ensure complete curing.

Step 4: Injection and Packing(Holding)

This is the stage where the material is melted and molded.

Plasticization and metering: The dried pellets are heated in the barrel to a molten state and are metered by the screw rotation, preparing a quantified amount of molten material for the next injection.
Injection and filling: The screw advances under high pressure, injecting the molten material at a set speed and pressure into the closed mold cavity. It is necessary to ensure a rapid and uniform filling of all details.
Pressure holding and retraction: After the mold cavity is filled, the machine enters the pressure holding stage, continuously applying pressure to the mold cavity to replenish the material that has decreased due to cooling shrinkage, preventing sink marks and dimensional inaccuracies.

Step 5: Cooling and Solidification

The molten material undergoes heat exchange with the circulating cooling medium (water or oil) within the mold cavity, thereby achieving solidification and shaping.

Cooling control: The cooling time must be sufficient to ensure that the product has sufficient rigidity before it is ejected. The uniformity of the mold temperature directly affects the dimensional stability and warpage deformation of the product.

Step 6: Mold Opening and Ejection

Demolding: The moving mold separates from the fixed mold once cooling is finished. To prevent stressing the partially cooled products, the demolding speed should be low.
Ejection: The product is forced out of the mold cavity by the ejection pin or ejection plate. To avoid placing too much stress on a particular component of the product, which could result in deformation or damage, the ejection system’s design should be balanced. Furthermore, the generated flash is sheared off in this step.

Step 7: Post-processing and Inspection

After the product is demolded, it still needs to undergo necessary processing before it can be considered a qualified product.

Trimming and secondary processing: Removing the gates and flashings by manual or mechanical means. According to requirements, surface treatments such as grinding, polishing, spraying and electroplating can also be carried out.
Quality inspection: Conduct full inspection or sampling inspection on the products, including:
- Examining the appearance for flaws like burning, bubbles, silver streaks, weld marks, and missing materials;
- Determining whether the part dimensions fall within the tolerance range using measuring instruments or a three-dimensional coordinate measuring device;
- Verifying adherence to usage requirements, performing functional or mechanical performance tests (such as impact strength) as needed.

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Mainstream ABS Materials Property Comparison

Grade / Brand	Manufacturer	Type / Key Features	Tensile Strength (MPa)	Flexural Modulus (GPa)	Notched Impact (kJ/m²)	Heat Distortion Temp (°C, 1.8 MPa)	Melt Flow Rate (g/10 min)	Density (g/cm³)	Shrinkage (%)	Rockwell Hardness (R)
PA-757	CHIMEI	General injection grade, high rigidity & gloss	47	2.2	19	~83	~19	1.19	0.3–0.6	100
PA-765 / PA-765A	CHIMEI	High flow / flame retardant ABS	~38	1.8	~23	~76–84	~46	1.17–1.19	0.3–0.6	100–101
HI-121H	LG Chem	General injection grade, high gloss, heat stable	~46	~2.3	~22	~79	22	—	—	—
GPM5500	SABIC (GE)	Multipurpose injection grade, high flow	—	2.30 (approx)	~10	~76	—	—	—	—
Cycolac MG47	SABIC	Balanced engineering performance	~44	~2.3	~23	~80–94	—	1.04	0.5–0.8	112
TERLURAN® HI-10	INEOS Styrolution	High impact ABS with very high toughness	38	~1.9	36	~97**	~5.5	—	—	—
TERLURAN® 967K	BASF/INEOS	General injection grade	50.0	—	—	—	—	1.03–1.04	0.4–0.7	—
Lustran® 348	INEOS Styrolution	General ABS	48.3	2.69	—	—	—	1.06	0.4–0.6	112
RTP 605 (30% GF)	RTP	Glass-fiber reinforced ABS	96.5	8.27	—	—	—	1.27	0.1–0.2	—

Note: Some commercial-grade products, such as TERLURAN® 967K and TERBLEND® S 7960S, do not have publicly available complete performance charts; to obtain the complete numerical data, please wait for our technicians to confirm after placing your order.

ABS Plastic Solutions

Our ABS Plastic Parts Production Capabilities

KingStar Mold’s state-of-the-art facility houses a wide range of injection molding machines specifically designed for ABS plastic production. This setup enables us to deliver ABS molding services with high precision and adaptability, meeting diverse client needs with exceptional quality.

Our team’s deep expertise in ABS enables us to utilize the latest technologies to produce durable, high-quality components for a wide range of applications.

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Tailored Material Solutions

At KingStar Mold, we provide customized ABS injection molding solutions designed to meet the specific requirements of our clients. We customize ABS to ensure optimal performance for your unique applications by adjusting properties such as toughness, fire resistance, and UV durability. Our team works closely with you to ensure the material properties align perfectly with your project’s demands, delivering high-quality, reliable results every time.

Expertise Across Industries

Precision Molding & Quality Assurance

With an integrated approach that includes in-house mold design, advanced finishing techniques, and stringent quality control, KingStar Mold ensures every ABS part is crafted with precision, exceptional aesthetics, and lasting quality.

Key Benefits of Choosing KingStar Mold for ABS Molding

ABS injection molding offers a range of advantages, making it an ideal choice for many applications.

Strength and Accuracy: ABS parts provide the impact resistance and dimensional stability needed for components such as dashboards, bumpers, and complex parts, ensuring both durability and precision.

Design Flexibility: ABS can be finished to a high standard, making it perfect for products that require both functionality and aesthetic appeal, such as toys, household appliances, and healthcare devices.

Cost-Effective for High-Volume Production: Thanks to its ease of processing and recyclability, ABS is an excellent material for industries like construction and packaging, where producing large quantities of durable, high-precision parts at a low cost is essential.

According to statistics, ABS is the most widely used material in all injection molding projects at KingStar Mold.

ABS Injection Molding Cases

Custom ABS molding requires careful drying and process control to prevent moisture-related defects, warping, and shrinkage, along with precise mold design to guarantee high-quality finishes and part integrity. This process demands the expertise of skilled engineers and advanced machinery to ensure optimal results.

Frequently Asked Questions

Are there any special considerations for coloring ABS in injection molding?webadmin2026-01-29T04:41:42+00:00

Are there any special considerations for coloring ABS in injection molding?

When coloring during ABS injection molding, several key aspects need to be particularly focused on to ensure accurate, uniform coloration without affecting the product’s performance.

1. Material drying: ABS resin is hygroscopic. Before coloring, it must be thoroughly dried; otherwise, residual moisture will affect the uniformity of the color.

2. Coloring agents: Choosing the appropriate coloring agent is the core of successful coloring. Consider the following properties:

Thermal stability: The coloring agent must be able to withstand the processing temperature of ABS (usually 210-260°C, and some heat-resistant grades can reach 280°C) without decomposing. Excessive heat will cause the color to darken, produce black spots or gas.
Dispersion: The coloring agent (especially pigments) must be uniformly dispersed in the ABS melt. Poor dispersion will result in color unevenness, color spots or gloss differences. Using high-quality color masterbatches is an effective way to improve dispersion.
Weather resistance and chemical stability: For outdoor or components requiring resistance to sunlight, choose UV-resistant pigments to prevent fading. At the same time, the coloring agent should not react adversely with ABS or other additives.
Special pigment considerations: Pigments containing metals (such as aluminum powder) or hard fillers may exacerbate wear on the screw and barrel, so their impact on the equipment must be taken into account.

3. Process parameters: While ensuring adequate plasticization, use the lower limit of the recommended temperature range to reduce the risk of thermal degradation of the coloring agent (note that different colors may have different heat absorption); using medium to high injection speeds helps achieve uniform color, but too fast a speed may cause shear overheating, leading to local scorching (especially when there is poor exhaust); appropriate back pressure helps improve the uniformity of plasticization and color dispersion, and the screw speed should not be too high to avoid excessive shear heat.

4. Mold and equipment:

Ventilation: Air trapping not only causes short shots but also the compression of high-temperature gas may cause local pigments to scorch, resulting in black streaks.
Cooling uniformity: Inhomogeneous cooling will cause different shrinkage rates in each area of the product, which may lead to visual color differences or uneven gloss.
Equipment cleaning: When changing colors, the barrel, screw, and nozzle must be thoroughly cleaned to prevent contamination from old materials. Especially when changing from a dark color to a light color, careful cleaning is particularly necessary.

5. Quality management: Different batches of base resin or color masterbatches may have minor differences. Strict incoming material inspection must be carried out; use professional color matching software and colorimeters (such as color difference meters) for color development and inspection to ensure that the color difference range meets the customer’s requirements.

Is ABS injection molding suitable for creating parts with intricate designs or thin walls?webadmin2024-11-10T07:06:02+00:00

Is ABS injection molding suitable for creating parts with intricate designs or thin walls?

Yes, ABS is suitable for intricate and thin-walled designs. By adjusting injection pressure and ensuring a precise flow rate, we achieve optimal fill for complex designs. Our engineers carefully design the molds to prevent issues like short shots or incomplete fills in thin-walled or detailed areas.

Are ABS resins suitable for low-volume production?webadmin2026-01-29T04:49:32+00:00

Are ABS resins suitable for low-volume production?

Injection molding requires the design and manufacture of molds, and its cost and manufacturing time will increase as the complexity of the part increases. Therefore, the initial investment for injection molding is very high, and a certain minimum production volume is required to recover the cost of mold design and manufacturing. This break-even point also depends on the expected selling price of the final product. If the selling price is higher (for example, the part is used for special purposes), then small batch production can be carried out. However, for low-cost parts, a large-scale production of tens of thousands of pieces is required to achieve cost-effectiveness.

If there are special requirements, it is recommended to use aluminum molds or silicone molds instead of the traditional multi-chamber steel molds. Aluminum molds have good heat conductivity, short production cycle, and the cost is approximately 30%-50% of that of steel molds. However, their lifespan is relatively short (about 50,000 – 100,000 times), making them suitable for small and medium batch production of several thousand pieces. Silicone molds are suitable for lower production volumes (from dozens to hundreds of pieces), and are often used in combination with polyurethane (PU) casting, but their material performance and efficiency are lower than direct injection molding.

What are the best applications for ABS injection molded parts?webadmin2026-01-29T03:19:11+00:00

What are the best applications for ABS injection molded parts?

ABS (Acrylonitrile-Butadiene-Styrene copolymer, where acrylonitrile provides hardness and chemical resistance, butadiene provides toughness, and styrene provides processability and surface gloss) injection molded parts have become the preferred choice in numerous industries due to their outstanding comprehensive properties – including excellent impact resistance, dimensional stability, processability, surface gloss, and cost-effectiveness:

1. Automotive Industry

ABS is widely used in interior and exterior components: dashboard, door panels, center console trim, seat parts, seat belt components; bumpers, grilles, mirror housings, body decorative strips, etc. This material provides good tactile feel, scratch resistance, and can achieve complex shapes and textures. Therefore, it is suitable for interior components, and its excellent impact resistance and weather resistance (especially the modified grades) can withstand external environmental challenges.

2. Consumer Electronics and Electrical Appliances

This field requires materials to have both structural strength, aesthetic appearance, and certain protective capabilities.

Electronic device casings: The casings of products such as laptops, televisions, printers, remote controls, routers, etc. ABS provides a good foundation for electromagnetic shielding, good dyeability, and excellent surface treatment adaptability (such as spraying, electroplating).
Household appliances: Inner linings of refrigerators, air conditioning panels, vacuum cleaner casings, coffee machines, microwave oven components, etc. The chemical resistance, heat resistance and easy cleaning properties of ABS are highly favored in such applications.

3. Consumer goods and toys

ABS is a pillar material in the consumer goods sector, balancing performance, safety and cost.

Toys: Such as Lego blocks, models, toy cars, etc. Their high strength and durability ensure safe play, and the components are easy to shape and have bright colors and detailed designs.
Daily-use products: Safety helmets, suitcases, kitchenware, bathroom accessories, etc. The lightweight and high toughness of ABS make it suitable for products that need frequent use and can withstand certain impacts.

4. Medical and Industrial Equipment

Medical equipment enclosures: Diagnostic equipment housings, handheld instrument handles, monitor housings, etc. Some medical-grade ABS materials have excellent biocompatibility, sterilizability, and dimensional stability. However, they are not suitable for implantable components.
Industrial components: Fan blades, pump housings, instrument covers, lightweight machine enclosures, pipe fittings, etc. Their corrosion resistance, rigidity, and ease of processing are suitable for various industrial environments. 。

5. Architecture and Furniture

The application of ABS in the field of architecture is mainly due to its weather resistance and dimensional stability.

Piping system: Pipes, pipe fittings (such as elbows, tees), ventilation ducts, etc.
Decorative and functional components: door and window profiles, baseboards, electrical switch panels, furniture handles, etc.

The reason why ABS injection molded parts can be the best choice in the aforementioned fields is fundamentally due to their outstanding cost-performance ratio and balanced performance. It is stronger than general plastics (like PP & PE), can achieve better surface effects, and is cheaper and easier to process than engineering plastics (such as PC, nylon, etc.). This unique positioning makes it irreplaceable in large-scale manufacturing that requires structural integrity, aesthetic appeal, and is cost-sensitive.

Can ABS parts be UV resistant, and how is this achieved?webadmin2026-01-29T03:22:26+00:00

Can ABS parts be UV resistant, and how is this achieved?

Individually, ABS does not inherently possess natural UV resistance. It may degrade under sunlight exposure over time. For applications requiring UV resistance, we recommend adding UV stabilizers to the raw ABS pellets before or during the molding process, or coating the surface of the components with a material that has UV resistance properties. This ensures that the components can maintain their appearance and structural integrity even when exposed to UV light for an extended period.

What are the common defects in ABS injection molded parts, and how can they be mitigated?webadmin2026-01-29T04:38:50+00:00

What are the common defects in ABS injection molded parts, and how can they be mitigated?

Defect	Main Visual Characteristics	Root Causes	Solutions
1. Sink Marks	Local depressions or dimples on the part surface, commonly appearing on the opposite side of ribs or thick wall sections.	Uneven cooling shrinkage of the material. The core of thick sections cools slowly, causing the surface to be pulled inward during shrinkage. Insufficient packing pressure or packing time fails to compensate for shrinkage.	Design: Optimize wall thickness with smooth transitions; avoid localized thick sections. Process: Increase packing pressure and extend packing time to ensure sufficient material compensation. Slightly reduce melt temperature and extend cooling time.
2. Warpage / Deformation	Part bends or twists after cooling, deviating from the intended shape.	Large differences in cooling rates across the part lead to uneven shrinkage and internal stress. Uneven ejection or premature demolding.	Mold: Optimize cooling channel layout to ensure uniform mold temperature. Improve ejector system balance. Process: Reduce mold temperature variation and extend cooling time. Lower injection pressure and speed to reduce internal stress. Design: Optimize part geometry, add reinforcing ribs, and avoid large flat areas.
3. Silver Streaks / Splay Marks	Silver or white streaks on the surface, typically aligned with the flow direction.	Moisture in the material vaporizes at high temperature; excessive melt temperature causes thermal degradation; poor mold venting traps air.	Material: Thoroughly pre-dry ABS resin (typically 80–85 °C for 2–4 hours). Process: Reduce melt temperature and screw speed to prevent overheating and degradation. Lower injection speed for smoother filling. Mold: Inspect and improve venting to allow trapped air to escape.
4. Short Shot / Incomplete Filling	Melt fails to completely fill the cavity, resulting in incomplete parts.	Insufficient injection pressure or speed; melt or mold temperature too low; gate or runner size too small; poor venting.	Process: Increase injection pressure, injection speed, and melt temperature. Raise mold temperature to improve flowability. Mold: Check and enlarge gate or runner dimensions; ensure adequate venting.
5. Burn Marks / Black Streaks	Black or dark brown marks on the surface or at the flow end of the part.	Air trapped in deep cavity areas is highly compressed and rapidly heated (“diesel effect”), causing material burning. Excessively high melt temperature.	Mold: Improve venting as a priority; add vents at flow ends or air-trap areas. Process: Reduce injection speed (especially in the final stage) to allow air to escape. Lower melt temperature.
6. Flash	Thin excess plastic along parting lines, inserts, or ejector pin holes.	Insufficient clamping force; excessive injection pressure; mold wear or poor parting surface fit; melt temperature too high.	Machine / Mold: Check and increase clamping force. Repair mold to ensure tight parting surfaces and restore worn areas. Process: Reduce injection pressure, injection speed, and melt temperature as appropriate.
7. Weld Lines / Knit Lines	Visible lines at locations where two or more melt fronts meet, usually with reduced strength.	Melt fronts split and rejoin in the cavity; the leading edges cool before meeting, resulting in poor fusion.	Process: Increase melt and mold temperatures to improve melt fusion. Increase injection speed to shorten cooling time before melt fronts meet. Mold: Adjust gate location to change weld line position. Add overflow wells or vents at potential weld line areas.
8. Delamination / Peeling	Layer-like separation or peeling on the part surface.	Material contamination (mixing incompatible plastics); severe moisture absorption; melt temperature too low causing poor plasticization.	Material: Ensure material cleanliness and avoid mixing different resin types or grades. Strictly follow pre-drying procedures. Process: Increase melt temperature and back pressure to ensure proper plasticization and homogenization.

The ABS injection molding defects need to be analyzed comprehensively by considering “materials – molds – processes – equipment”. Usually, one defect may be caused by a combination of multiple reasons. When conducting the investigation, the principle of starting from the simple to the complex and from the surface to the interior should be followed: first, confirm whether the materials are fully dried; second, check whether the process parameters are within the reasonable range; finally, review whether there are fundamental limitations in the mold design. Through this structured approach, the root cause of the problem can be effectively identified, and long-term corrective and preventive measures can be implemented, thereby achieving stable, efficient, and high-quality production.

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