Last Updated: March 2026
Injection Moulding Australia — From Prototype Tooling to Production
Rapid Manufacturing provides injection moulding services across Australia — from low-cost aluminium prototype tooling through to hardened production steel tools for millions of shots. Our supplier network holds ISO 9001:2015 certification as a minimum, with ISO 13485 certified medical-grade suppliers available. Free DFM analysis, quotes within 2 business days, no minimum order on moulded parts once tooling is in place.
Tooling Options
Aluminium Rapid Tooling
Fastest and cheapest path to real injection moulded parts. Suitable for validating design and material before production tooling investment.
Semi-Hardened Steel (P20)
Good durability at moderate cost. Suitable for most medium-volume production requirements. Can be polished to Class A surface finish.
Hardened Steel (H13)
Maximum tool life for high-volume production. Higher initial investment amortised over millions of parts. Required for abrasive materials (glass-filled, mineral-filled).
Injection Moulding Materials
| Material | Key Properties | Typical Applications |
|---|---|---|
| ABS | Good impact resistance, easy to paint, stable dimensions | Consumer electronics, automotive interior, housings |
| Polypropylene (PP) | Lightweight, chemical resistant, living hinges | Packaging, medical consumables, automotive |
| Polycarbonate (PC) | Very high impact resistance, transparent, UV stable | Lenses, lighting, safety equipment |
| PC/ABS Blend | Combines PC strength with ABS processability | Automotive, electronics, enclosures |
| Nylon PA6 / PA66 | High strength, wear resistance, low friction | Gears, bearings, under-hood automotive, cable ties |
| Acetal (POM) | Low friction, high stiffness, excellent fatigue resistance | Gears, bearings, plumbing components |
| TPU / TPE | Flexible, rubber-like, abrasion resistant | Grips, seals, over-moulding, wearables |
| PEEK | Extreme temperature resistance, biocompatible, chemical resistant | Medical implants, aerospace, high-temp industrial |
Design for Mouldability — Key Guidelines
- Draft angles (0.5–3°)
All surfaces perpendicular to the mould parting line need draft angle for clean part ejection. Minimum 0.5–1° for smooth surfaces, 3–5° for textured surfaces.
- Uniform wall thickness
Keep wall thickness as uniform as possible (typically 1.5–4mm for most materials). Thick sections cause sink marks, warpage, and extended cycle times.
- Avoid undercuts
Undercuts require side-actions or lifters in the tool, significantly increasing tooling cost. Redesign to eliminate undercuts where possible, or flag them explicitly for side-action quoting.
- Add radii to all internal corners
Internal corners with R0 (sharp corners) create stress concentrations and cause tool cracking. Minimum R0.5mm on all internal corners.
- Gating and ejector pin placement
Consider where the gate (injection point) and ejector pins will be. Gate marks and ejector pin marks are permanent cosmetic features — position them on non-cosmetic surfaces.
Rapid Manufacturing's Injection Moulding Process
- 1Submit STEP files and drawing
Upload 3D files and any 2D drawings with wall thickness, surface finish, and tolerance requirements.
- 2Free DFM analysis
We review your part for mouldability — draft angles, wall thickness, undercuts, parting line placement, gate location. We recommend changes before tooling is made.
- 3Tooling quote and approval
You receive pricing for tooling (by type), part price at your volumes, and lead time. Approve and pay to begin tool manufacture.
- 4Tool manufacture and first articles
Tool is machined, first article parts are produced and measured against your drawing. You approve first articles before full production.
- 5Production and delivery
Production parts are moulded to your approved first article standard, inspected, and shipped directly to you.
Get Your Injection Moulding Quote
Upload your STEP file for a free DFM analysis and tooling quote within 2 business days.
Request a QuoteFrequently Asked Questions
How much does injection mould tooling cost in Australia?
Rapid prototype tooling in aluminium typically costs $3,000–$15,000 AUD depending on part complexity and number of cavities. Production-grade P20 steel tooling ranges from $15,000–$80,000+. These are indicative ranges — contact Rapid Manufacturing with your part files for an accurate quote.
What is rapid tooling for injection moulding?
Rapid tooling refers to injection mould tools made from aluminium or softer steel grades (rather than hardened P20 or H13). Aluminium tools are faster to machine, cheaper to produce (typically 40–60% lower cost than production steel tools), and suitable for up to 5,000–20,000 shots depending on material. They are ideal for prototyping, bridge production, and market validation before investing in full production tooling.
What plastic materials can be injection moulded?
Rapid Manufacturing can source injection moulding in virtually any thermoplastic including: ABS, Polypropylene (PP), Polyethylene (PE), Polycarbonate (PC), Nylon (PA6, PA66), Acetal (POM/Delrin), PEEK, TPU/TPE (flexible), PC/ABS blends, glass-filled grades, and fire-retardant grades. Material selection depends on mechanical requirements, chemical exposure, temperature, and regulatory requirements.
How long does injection mould tooling take to produce?
Aluminium rapid tools typically take 2–4 weeks to produce. Production steel tools take 4–8 weeks depending on complexity. First article parts are provided for approval before full production runs begin.
What is bridge tooling?
Bridge tooling is a strategy where you produce a lower-cost tool (often aluminium or semi-hardened steel) to produce parts while your full production tool is being manufactured or while you are still validating the design. Bridge tools typically produce 1,000–20,000 parts and are particularly useful for managing supply while finalising the product design.
What draft angle is required for injection moulded parts?
Most injection moulded parts require a minimum draft angle of 0.5–1° on vertical surfaces to allow the part to release cleanly from the mould. Textured surfaces typically require 3–5° draft depending on texture depth. Surfaces parallel to the draw direction (0° draft) are achievable but increase tool cost and part defect risk. Rapid Manufacturing's DFM analysis will identify any surfaces requiring draft angle adjustment.
Can Rapid Manufacturing handle medical-grade injection moulding?
Yes. Rapid Manufacturing has access to ISO 13485:2016 certified injection moulding suppliers for medical device components. These facilities maintain class-specific cleanrooms, material traceability, and documentation systems required for medical device manufacturing.