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Advanced Injection Press Fleet: 6T to 550T
Contract molding starts with putting each mold in the right press. A press that is too big wastes energy and can hold resin in the barrel too long. A press without enough clamp for the projected area flashes at the parting line. With more than 500 presses, TK can match the press to the mold instead of the other way around.
Fleet Composition and Technology
TK’s production fleet is mostly Japanese and European machines, including JSW, Sumitomo, Fanuc, Toyo, Nissei, Sodick, Arburg, Engel and KraussMaffei. The 2026 count is 503 presses:
- 343 horizontal presses: consumer electronics, automotive, packaging, personal care and medical parts.
- 60 two shot (2K) and 3 three shot (3K) presses: hard and soft materials or two colors bonded in one molding cycle.
- 40 vertical presses: insert molding over metal, glass, ceramic and PCBs, including low pressure molding over circuit boards.
- 25 high speed presses: thin wall parts, with stable production under 0.6 mm wall.
- 32 LSR presses: liquid silicone parts and LSR overmolded onto plastic or metal.
ISO 13485 Medical Molding and Validation
Medical and healthcare parts need a documented, validated process before the first production lot ships. TK has held ISO 13485 since 2010 and issued its GMP statement in 2019. TK also builds high cavitation molds for disposables such as syringes, infusion sets, hemodialysis parts and lab consumables, so the mold and the molding process are developed by one team.
Medical Launch and Validation Steps
Medical programs follow TK’s launch process from ESI and DFM through tooling trials, first article inspection and engineering changes, then validation before release to mass production:
- Installation Qualification (IQ): the press, mold, auxiliaries and gauges are installed, calibrated and documented.
- Operational Qualification (OQ): the process window is tested at its limits to show good parts across the window.
- Performance Qualification (PQ): production runs at nominal settings show the process is stable and capable.
- Inspection: CMM, optical measurement, CT and CCD vision inspection in TK’s lab.
High-Performance Engineering Resin Expertise
TK molds about 7,000 tons of plastic a year, from commodity resins to glass filled engineering plastics, LSR and PEEK. High temperature resins need hot oil or electric mold heating, tight barrel temperature control and good venting, which TK builds into the mold and the process setup.
| Material | Example Grades | Melt Temp (°C) | Mold Temp (°C) | Why It Is Used |
|---|---|---|---|---|
| PEEK | Victrex 450G, Solvay KetaSpire | 360 to 400 | 170 to 200 (hot oil or electric) | High heat and chemical resistance |
| PPS | Ryton, Fortron | 310 to 340 | 135 to 150 | Dimensional stability, inherent flame resistance |
| PC | Lexan, Makrolon | 280 to 320 | 80 to 120 | Clarity and impact strength |
| PA66 with 50% glass | Zytel, Durethan | 280 to 305 | 70 to 120 | Stiffness and strength for metal replacement |
| LSR | Silopren, Elastosil | Kept cool, about 20 to 30 | 150 to 200 (heated mold cures the part) | Flexible, heat resistant, used for seals and medical parts |
Typical ranges from resin supplier data sheets. Each grade has its own data sheet, and TK sets the final values during process development.
Multi-Shot (2K/3K) Chemical Bonding
Molding a rigid substrate and a soft seal or grip in one cycle removes manual assembly, adhesive and a source of leaks. TK runs 60 two shot and 3 three shot presses, plus over molding, soft and hard bonding, and LSR over molding onto engineering plastics and metal. Learn more on our multi shot injection molding page.
Automated Robotic Handling and Degating
High volume cells run with take out robots and end of arm tooling built for the part. Vacuum cups and grippers pick parts without touching cosmetic surfaces, and runners are separated for regrind. Automation also covers insert loading, in mold labeling and decoration, degating and automated assembly lines.
TK’s MES and ERP systems connect the production floor. In TK’s smart factory, 95% of key equipment is connected, production efficiency improved 18.6%, and delivery cycle time dropped 30%.
Secondary Decoration, Coating, and Final Assembly
Every hand off between vendors adds freight, handling damage and another quality system to manage. TK paints, prints, decorates and assembles in house, so molded parts can leave as finished products.
In House Secondary Operations
Automatic spindle lines 450 to 560 m long, each with 3 painting and 3 baking stations. Class 100K clean room and Class 10K clean spray booth. Solvent and waterborne paints.
Non conductive vacuum metallization gives a chrome or brushed metal look that does not block wireless signals.
Pad printing, silk screen, 6 color offset and digital printing, laser etching and foil stamping.
Ultrasonic welding, heat staking and lamination, automatic assembly lines, and kit assembly and packaging lines.
Interactive Press Tonnage Estimator
Enter your part, cavitation and annual volume. The estimator works out the clamp tonnage range, shows where that press size sits in TK’s fleet, and tells you how many press hours and presses your program needs. Open “Show the math” to see every step with your numbers.
Show the math
Clamp tonnage uses common rule of thumb clamp factors by resin. Thin walls, long flow lengths and high cavity pressure need more, and TK confirms the press with Moldflow during DFM. Fleet counts are TK’s 2026 press list. Default numbers are an example only.
Technical Sourcing FAQ: Contract Injection Molding
Looking for a Scalable Contract Molding Partner?
Send your part files, annual volumes and quality requirements to Brandon Henderson, Technical Sales Support Manager for the Americas. He will come back with a molding plan, mold build timing and a piece price quote.