Over two decades of plastic injection moulding expertise — cutting-edge machinery, hardened-steel tooling, and rigorous quality systems that deliver from first prototype to millions of units.
Engineering-grade resins, speciality compounds, and high-performance polymers.
Hardened tool steels rated for 500,000+ shots with dimensional stability maintained throughout the tool's life.
Sub-micron wire electrical discharge machining for complex core and cavity geometries impossible by conventional cutting.
High-speed 3-axis CNC machining of base plates, runners, and cavity inserts to ±0.5 mm positioning accuracy.
No outsourcing. Full control of the mould build schedule — faster iterations, lower costs, tighter tolerance handoffs.
Part geometry, tolerances, volume, material, and end-use environment reviewed in detail.
Resin grade chosen based on mechanical, thermal, and regulatory requirements.
3D CAD design with DFM analysis, cooling simulation, and gate optimisation.
CNC and EDM machining of hardened steel core and cavity inserts.
First article samples produced and measured against drawing tolerances.
Validated process parameters locked; full production runs initiated.
100% visual inspection and CMM measurement at every production shift.
Insert fitment, sub-assembly, and functional testing as required.
Customer-specified packaging, labelling, and anti-static protection.
On-time dispatch with full traceability documentation and Certificate of Conformance.
At Plastifusion, quality is embedded at every process stage — not added at the end. Our certified QMS, precision measurement hardware, and statistical controls make conformance predictable, traceable, and repeatable.
Metal inserts co-moulded for maximum pull-out strength.
Two-shot sequential for multi-material assemblies.
Snap-fit, ultrasonic welding, sub-assembly completion.
Deburring, pad printing, UV coating, surface treatment.
Custom pack with brand labelling and bar-coding.
Under-bonnet housings, sensor carriers, clips, and brackets to OEM tolerances.
EMC-compliant enclosures and PCB assembly housings.
Aesthetically finished closures, handles, and structural frames.
Cleanroom-compatible diagnostic housings, trays, and disposables.
Junction boxes, cable management, and heavy-duty brackets.
Expedited tooling paths and reserved machine slots for time-critical programmes.
Stored process parameters allow rapid re-initiation of any validated job.
In-house tooling eliminates third-party mark-ups; high-efficiency cycles cut unit cost.
DFM reviews, material guidance, and tooling consultation from day one.
P20 and H13 moulds built for longevity with minimal dimensional wear.
Single-vendor ownership from resin intake to packaged, labelled delivery.
Expedited tooling paths and reserved machine slots for time-critical programmes.
Stored process parameters allow rapid re-initiation of any validated job.
In-house tooling eliminates third-party mark-ups; high-efficiency cycles cut unit cost.
DFM reviews, material guidance, and tooling consultation from day one.
P20 and H13 moulds built for longevity with minimal dimensional wear.
Single-vendor ownership from resin intake to packaged, labelled delivery.
