Custom Plastic Injection Molding Services
Thermoplastic injection molding in Phoenix, Arizona, from prototype tooling and bridge production to multi-cavity programs of 10 million parts a year. 50+ engineering resins, presses under 200 tons, scientific molding, documented inspection, assembly and kitting under one roof.
Production volumes
Two ways to run a program, one quality system behind both.
Low volume and bridge production
Low volume injection molding covers runs from a few hundred to tens of thousands of parts: pilot builds, market tests, bridge production while a hard tool is cut, and service parts for legacy products. We quote aluminum or P20 tooling with shorter lead times and lower tool cost, mold in the production resin so the parts you test are the parts you ship, and carry the tool forward if volumes grow.
Typical lead time is 5 to 10 business days for rapid aluminum tooling and 2 to 3 weeks to first parts.
High volume production
High volume injection molding is where Legacy was built. Multi-cavity and family molds, hardened steel tooling rated for a million-plus cycles, in-process inspection and scheduled releases keep per-part cost down and delivery predictable at 100,000 to 10 million parts a year.
We run blanket orders with weekly or monthly releases, hold safety stock to your Kanban, and record inspection data on critical dimensions every lot.
Press and process capabilities
| Capability | What we run |
|---|---|
| Process | Thermoplastic injection molding, scientific molding with a documented, locked process sheet for every tool |
| Press range | Presses under 200 tons. Small and mid-size precision parts; we do not run large housings or structural moldings |
| Tooling | Single-cavity prototype through multi-cavity and family production molds; hot and cold runner |
| Materials | ABS, PC, PC/ABS, nylon and glass-filled nylon, PP, HDPE and LDPE, TPE and TPU, acetal, PEEK and Ultem, flame-rated and ESD grades, 50+ resins |
| Secondary operations | Ultrasonic welding, heat staking, insert installation, pad printing, light assembly, kitting and custom packaging |
| Quality | Documented quality system: in-process inspection on critical dimensions, first article inspection reports, material certs and lot traceability |
| Volumes | Prototype and bridge runs through 10 million+ parts a year |
| Location | Phoenix, Arizona; shipping across the Southwest and nationally |
Secondary operations and assembly
Parts rarely ship straight off the press. We weld, stake, insert, print, assemble, kit and package in the same building, so your receiving dock gets a finished component rather than a bag of pieces.
- Ultrasonic welding and heat staking
- Threaded insert installation (heat or ultrasonic)
- Pad printing and part marking
- Sub-assembly and hardware installation
- Kitting, bagging, labeling and custom packaging
- Vendor-managed inventory and scheduled releases
Quality system
Every program runs on a process sheet developed through scientific molding and locked before production. Critical dimensions are checked in-process with calibrated gauges, verified on the surface plate, and recorded in a first article inspection report before production starts. Material certifications and lot traceability ship with the parts.
- First article inspection (FAI) with a dimensional report
- In-process checks on critical-to-quality dimensions
- Material certs and lot traceability
- Documented, locked process sheet for every tool
- Inspection records to your drawing on request
Industries we mold for
Frequently asked questions
How much does injection molding cost per part?
Piece price depends on part size, resin, cycle time, cavitation and annual volume. Small parts in commodity resins at high volume run pennies; large or engineering-resin parts run dollars. Tooling is a separate one-time cost. Send CAD and your annual volume and we will quote both within one to two business days.
What is the minimum order quantity?
There is no fixed minimum. Tooling investment sets the practical floor, and bridge or prototype tooling makes runs of a few hundred parts economical. Our strength is programs from 100,000 to 10 million parts a year.
How long does tooling take?
Rapid aluminum prototype tooling in 5 to 10 business days. Production steel tooling typically 6 to 12 weeks from design approval to first article, depending on cavitation and complexity.
Can you run a mold we already own?
Yes. Our mold transfer program covers tool inspection, process development, first article and production restart for molds coming from another molder, including overseas. See the tooling page for the checklist.
Do you offer design for manufacturability (DFM) review?
Every quote includes DFM feedback on draft, wall thickness, ribs and bosses, gate location, undercuts and tolerances. Fixing those before steel is cut is the cheapest change you will ever make to a molded part.
Quote an injection molding program
Upload CAD, tell us the resin if you know it and the annual volume. Pricing and DFM notes within one business day.
Phoenix, AZ 85040
480-256-9773
b.hanke@legacy-molding.com
Mon–Fri 8:00 AM – 5:00 PM