Finding an injection molding partner with the right equipment capacity for larger plastic components often proves difficult for manufacturers. Many molding companies lack the heavy-duty presses needed to handle bigger parts or high-volume production runs. This forces businesses to work with multiple vendors or settle for subpar results.
At American Plastics, we’re a plastic injection molder with a 400-ton press. Our Arizona facility houses this press alongside our full range of molding equipment to handle large parts with tie bar spacing up to 36 inches and shot sizes up to 54 ounces. Read on to learn more about our 400-ton press capabilities and how they can support your next plastic manufacturing project.
What is a 400-Ton Injection Molding Press?
A 400-ton injection molding press generates 400 tons of clamping force to hold mold halves together during the injection process. This clamping force prevents the mold from opening under the pressure of molten plastic being injected into the cavity. The tonnage rating directly correlates to the size and complexity of parts the machine can produce.
These machines feature larger platens and wider tie bar spacing compared to smaller presses. The increased platen size accommodates larger molds, while wider tie bar spacing allows taller molds to fit between the press columns. Higher tonnage presses also deliver greater shot capacity, enabling the production of thicker-walled parts or multiple cavities in a single cycle.
Understanding the components of this machine helps explain how press tonnage affects manufacturing capabilities:
- Clamping Force: Pressure that keeps mold halves closed during injection and is measured in tons
- Platens: Flat surfaces that hold and support mold halves during molding operations
- Tie Bar Spacing: Distance between the four corner rods connecting platens, and determines the maximum mold height
- Shot Capacity: The maximum amount of molten plastic injected in one cycle and measured by weight or volume
American Plastics is an Injection Molder with a 400-Ton Press
At American Plastics, we’ve provided ISO 9001-certified injection molding services in Arizona for over four decades. Our facility houses 13 injection molding presses with capacities from 55 to 400 tons. We maintain UL-approved status and serve the electrical, consumer, and construction industries through scientific molding, traditional molding, and insert-over molding techniques.
Our team works with both commodity and engineering thermoplastics to meet different project requirements. We handle traditional resins like polyethylene and polystyrene alongside advanced materials such as nylon, polycarbonate, ABS, Acetal, HDPE, LDPE, PVC, and Santoprene. These material options allow us to match specific thermal performance, mechanical properties, chemical resistance, and surface finish requirements across various industries.
Advanced Injection Molding Applications
A 400-ton press supports advanced molding techniques for parts with specific functional or material properties. It can be configured for several advanced production methods:
Multi-component and multi-material molding
This process combines two or more materials into a single component during one automated cycle. A 400-ton press accommodates the rotating molds required for this technique, often called 2-shot molding or overmolding. Common products include medical instruments with firm bodies and soft grips or automotive dashboards with both hard and soft-touch surfaces.
Gas-assist injection molding
This technique uses high-pressure nitrogen gas to create hollow channels within a plastic part. The gas pushes the molten resin against the mold walls, which helps eliminate surface imperfections like sink marks and reduces warping. It is used to produce large, hollow components with a high-quality surface finish, such as automotive grab bars or appliance handles.
Thin-wall molding
Thin-wall molding requires the high speed and precise pressure control available on certain 400-ton press configurations. The process results in lighter-weight parts, uses less material, and allows for shorter production cycle times. This method is suitable for producing items like food and beverage containers or lightweight electronic enclosures.
In-mold labeling and decorating
This automated process applies a pre-printed label or decorative film to a part during the molding cycle. The label fuses directly to the component’s surface, creating a durable and seamless finish that resists wear. It removes the need for secondary labeling operations and is used for branded packaging or household products.
High-precision and micro-molding
An all-electric 400-ton press provides the repeatability and accuracy needed to produce parts with very tight tolerances. This capability is necessary for manufacturing intricate components where dimensional accuracy is a primary requirement. Applications include medical labware like microplates and fluidic devices or small electronic connectors.
Our Value-Added Services
In addition to our injection molding and design & tooling capabilities, we also offer the following value-added services:
Injection Molder with Assembly, Packaging, and Drop Ship Capabilities
American Plastics manages complete production from molding through final packaging and shipping. Our assembly operations produce fully finished, labeled, filled, and packaged products without parts leaving our facility. This approach eliminates the coordination challenges and delays associated with managing multiple third-party providers.
In-House Printing, Filing, and Labeling
Our facility houses printing and labeling equipment that applies product designs and required markings directly to molded parts. We perform screen printing, pad printing, heat transfer labeling, and hot stamping on various materials and surface textures. These capabilities allow us to add corporate logos, product numbers, patterns, artwork, and text to finished components.
Ultrasonic Welding and Final Assembly
Ultrasonic welding joins multiple plastic components using high-frequency mechanical vibrations rather than adhesives or mechanical fasteners. This process creates clean, precise bonds that meet requirements for automotive, electronic, and medical applications. Our assembly team also installs screws, springs, clasps, and other hardware components to complete finished products.
Typical Products/Components Produced by a 400-Ton Press
A plastic injection molder with a 400-ton press produces larger plastic components that require substantial clamping force and shot capacity. These machines excel at manufacturing thick-walled parts, multi-cavity molds, and components with complex geometries that smaller presses cannot accommodate.
There are several different types of components that are best suited for a 400-ton injection molding press. These include, but are not limited to:
- Automotive Interior Panels: Dashboard components, door panels, and console housings that require large surface areas and precise dimensional stability.
- Industrial Housings and Enclosures: Equipment covers, electrical boxes, and protective casings that need thick walls and robust construction.
- Large Consumer Product Components: Appliance parts, furniture components, and recreational equipment pieces with substantial size requirements.
- Multi-Cavity Small Parts: High-volume production runs of smaller components molded simultaneously in large multi-cavity molds.
- Thick-Walled Technical Parts: Components requiring substantial wall thickness for strength, such as structural brackets and heavy-duty connectors.
How to Choose the Right Tonnage Press for Your Project
Start by calculating your part’s projected area and multiplying it by the material’s injection pressure to determine the minimum clamping force needed. Add a safety margin of 10-20% to this calculation to account for material variations and processing conditions. This total represents the minimum press tonnage required for your project.
Consider your production volume and part complexity when selecting from available press sizes above your minimum requirement. Higher tonnage presses often provide better dimensional stability and longer tool life for demanding applications. Evaluate whether multi-cavity tooling makes sense for your volume requirements, as this approach may justify moving to a larger press for improved cycle efficiency.
Choose American Plastics for 400-Ton Injection Molding
A 400-ton injection molding press opens up new manufacturing possibilities for larger components and higher-volume production runs that smaller equipment cannot handle. This capability becomes essential when your project demands substantial clamping force, wider tie bar spacing, or increased shot capacity to meet quality and production requirements.
At American Plastics, we combine our 400-ton press with over four decades of ISO-certified molding experience to deliver reliable results for complex projects. Our facility also provides secondary operations like assembly, packaging, and finishing to streamline your entire production process.
Click below to get a quote and discover how our heavy-duty equipment can support your next manufacturing needs.
