At Dhanya Plastics & Foams, we employ stringent quality control measures throughout our injection moulding process for toys and sports plastic parts. This ensures we create strong, durable components designed to withstand rigorous use in play and sports environments. Our expertise in advanced plastic materials and precision moulding techniques allows us to tailor the strength, flexibility, and safety of every part to meet the unique demands of toys, athletic gear, and recreational equipment.
Frequently Asked Questions
Plastic toys are primarily made through injection moulding. Molten plastic is injected into a precision-designed mold under high pressure. Once cooled, the mold opens to release the finished toy part. This process ensures consistency, intricate detailing, and scalability for high-volume production.
Toys are manufactured by:
- Designing the mold: Custom molds are created for each toy component.
- Material selection: Child-safe plastics like ABS, PP, or HDPE are chosen.
- Injection moulding: Molten plastic is injected into the mold.
- Cooling & ejection: Parts are cooled, removed, and assembled (if needed).
- Finishing: Painting, polishing, or adding decals for aesthetics.
Common toy-safe plastics include:
- ABS (durable, glossy finish for LEGO-like toys).
- PP (flexible, chemical-resistant for rattles or outdoor toys).
- HDPE (sturdy, FDA-approved for teething toys).
- TPE/TPR (soft, rubber-like for squishy toys).
HDPE (High-Density Polyethylene) is preferred for toys because it is:
- Non-toxic (meets FDA/EN71 safety standards).
- Impact-resistant (withstands rough handling).
- Easy to clean (ideal for bath or outdoor toys).
- Recyclable (eco-friendly option).
Yes! Plastic cups are often made via injection moulding for uniformity, speed, and cost-efficiency. However, thin-walled items like cups may also use thermoforming.
Yes. Child-safe materials like ABS, PP (Polypropylene), and TPE (Thermoplastic Elastomer) are non-toxic, BPA-free, and comply with global safety standards (e.g., ASTM F963, EN71).
Yes, the outer shell of football helmets is typically injection moulded using high-impact plastics like polycarbonate (PC) or ABS. This process ensures precision, durability, and consistent thickness to meet safety standards for impact absorption. Inner padding often uses foams (e.g., EVA) for additional protections.
Injection-molded parts are highly durable, with impact-resistant plastics (e.g., PC/ABS blends) and UV-stabilized materials for outdoor sports equipment.
For prototypes or small runs (<1,000 units), 3D printing may be cheaper. Injection moulding becomes cost-efficient for larger orders due to lower per-unit costs.
Yes. High-capacity machines and automated systems ensure consistent quality for bulk orders of items like bicycle components or goalposts.