Project Evaluation & DFM Analysis
Review product structure, size, material, and appearance requirements. Conduct DFM analysis to identify potential risks in flow, cooling, warpage, and demolding, and provide optimization suggestions in advance.
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Large & Extra-Large Injection
Large and extra-large injection molding focuses on parts with greater surface area, height, and weight. Compared to smaller components, it requires higher clamping forces and greater injection pressures, emphasizing process stability and precision.
Key Capabilities
- Professional large-scale injection molding equipment and mature technical team
- Custom mold design and manufacturing for extra-large components
- Strict quality control from prototyping to mass production
- Stable production cycle, on-time delivery, and competitive pricing
- Comprehensive after-sales support and technical consultation
Talk to Our Team 
5,500 tons
Clamping Force
±0.2 mm
Thickness Control
2,500 mm
Maximum Part Length
5–120 kg
Part Weight Range
Key Process Challenges
- Material Flow Control
During large-part injection molding, molten plastic must travel long flow paths. Any uneven flow can result in short shots, weld lines, or air traps in the molded part. - Cooling Efficiency:
Thicker cross-sections in large parts require longer cooling times, increasing cycle time. Uneven cooling can cause warpage and internal stress in the molded components. - Mold Strength & Stability
Due to their size, molds for large parts must withstand higher pressures and expansion. The mold must be strong and stable throughout the process. - Machine Requirements
High-tonnage injection machines are required to ensure sufficient clamping force. Injection speed and pressure must be carefully controlled to avoid defects in the molded parts.
How Do We Mold Extra-Large Components?
We focus on large-scale and extra-large injection molding manufacturing with professional equipment, mature process and strict quality control,
providing reliable one-stop production solutions for oversized plastic components.
Ultra-Large Injection Support
Our facility has high-tonnage injection machines for ultra-large parts, from TV housings to automotive panels and battery bases. We provide mold setup, precision injection, quality inspection, and post-molding handling for stable oversized production.
Custom Mold Design
We provide targeted mold development for large & extra-large injection products, with high-rigidity mold structure, optimized runner layout and balanced cooling system, effectively reducing warpage, shrinkage and deformation in large part molding.
Precise Process Control
The whole process of large & extra-large injection adopts precise parameter control of temperature, pressure, speed and holding pressure, ensuring consistent wall thickness, stable size and high repeatability of mass-produced large plastic parts.
Quality Assurance System
We have established a special quality control standard for large & extra-large injection molding, covering raw material testing, online production monitoring and full-size finished product inspection, to ensure that each large injection part meets structural strength and assembly requirements.
Customized Solutions
According to customer product size, structure and application scenarios, we provide personalized large & extra-large injection solutions, supporting material selection optimization, structural improvement and mass production, to meet the needs of various industrial large plastic parts.
Automation & Handling
We utilize robotic arms, synchronized handling systems, and specialized lifting equipment to safely and efficiently remove, transport, and assemble oversized injection-molded parts, reducing labor costs and ensuring consistent production quality.
Suitable Materials
Aluminum Alloys
- 6061
- 7075
- 2024
- 5083
Stainless Steel
- 304
- 316
- 17-4
- 15-5
Copper Alloys
- C1100
- C36000
- C17200
Titanium Alloys
- Ti-6Al-4V
- Ti-5Al-2.5Sn
Thermoplastic
- ABS (Acrylonitrile Butadiene Styrene)
- PE (Polyethylene)
- PP (Polypropylene)
- PVC (Polyvinyl Chloride)
- PC (Polycarbonate)
- POM (Polyoxymethylene)
Engineering
- PEEK (Polyether Ether Ketone)
- PPS (Polyphenylene Sulfide)
- PTFE (Polytetrafluoroethylene)
Surface Finishing Options
Painting & Coating
Improve appearance, weather resistance and scratch resistance.
Texture Finish
Add matte, leather grain or custom textures to hide marks.
Plating
Print logos, text and patterns on large parts.
Laser Engraving
Permanent marking with high precision and no fading.
Polishing
Achieve smooth and high-gloss surface finish.
Anodizing
Enhance outdoor weatherability and service life.
Key Applications
Large & Extra-Large Injection Process
Mold Design & Development
Design high-rigidity mold structure, runner system, cooling circuit, and ejection system suitable for large parts. Complete mold manufacturing, precision machining, and assembly to ensure stability under high pressure and long-term production.
Material Selection & Preparation
Select appropriate plastic or metal materials according to product performance requirements. Conduct drying, mixing, and quality inspection to ensure stable material properties during injection.
Machine Setting & Process Debugging
Use high-tonnage injection molding machine to set clamping force, injection speed, pressure, temperature, holding pressure, and cooling time. Optimize parameters to avoid short shots, weld lines, warpage, and trapped air.
Large Part Injection Molding Production
Stable mass production of large & extra-large parts under controlled environment. Real-time monitoring of pressure, temperature, and cavity status to ensure consistency of each product.
Cooling, Shaping & Demolding
Controlled cooling to reduce internal stress and warpage. Use reasonable ejection system to ensure safe demolding of large parts without deformation or damage.
Inspection & Quality Control
Carry out dimensional inspection, appearance inspection, structural testing, and assembly verification. Establish strict standards to ensure large parts meet drawing and application requirements.
Packaging & Delivery
Use professional protective packaging for large-sized products to avoid scratches and deformation during transportation. Arrange on-time delivery according to customer requirements.
Our Capabilities
Our workshops are equipped with 30+ injection molding machines from top brands like Chuan Hsiung and Haitian, with clamping forces ranging from 50 to 2500 tons.
The extra-large tonnage injection molding machines can mold 100-inch TV housings, produce bumpers and battery trays for traditional and new energy vehicles, and provide injection molding services for military applications.
| Equipment Name | Brand | Tonnage/Model | Quantity |
| Injection Molding Machine | Chen Hsong | 128T / 208T / 328T / 468T | 1 |
| Injection Molding Machine | Chen Hsong | 800T / 1450T / 2500T | 1 |
| Injection Molding Machine | DONGHUA | 320T / 380T / 450T / 1500T | 1 |
| Injection Molding Machine | DONGHUA | 500T / 750T | 2 |
| Injection Molding Machine | Chen Hsong | 1000T | 2 |
| Injection Molding Machine | Haitian | 90T | 2 |
| Injection Molding Machine | Haitian | 120T / 160T / 200T / 320T / 360T / 1200T | 1 |
Zhen Xiong Injection Machine Cluster
Multiple Zhen Xiong injection molding machines (1000–2500 tons)
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What’s the maximum part size you can produce?
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We focus on large & extra-large injection molding and can produce oversized parts according to customer requirements with our high-tonnage machines.
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What materials are available for large injection parts?
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We support various plastics (PP, ABS, PC, PA, modified materials) and metal inserts for structural reinforcement.
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Do you provide mold design and manufacturing for large parts?
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Yes, we provide custom high-rigidity mold design, processing and commissioning for large & extra-large injection.
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How do you control warpage and deformation in large parts?
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Through optimized cooling systems, balanced flow design, precise process control and mold stability.
Start Your Project Inquiry
Your information is kept confidential and reviewed directly by our engineering team. We typically respond within 1 business day with practical technical feedback.
