Injection Molding

Injection Molding Services That Deliver Consistency, Speed, and Scale

Injection molding is at the heart of what we do at Sussex IM. With more than 65 molding machines and decades of hands-on experience, we support high-volume production with the precision and repeatability our customers count on.

As a full-service plastic injection molding manufacturer, we manage every stage in-house, from design for manufacturing and tooling to automation, assembly, and delivery. That means tighter control, faster response times, and seamless execution across the board.

Our presses range from 25 to 725 tons, giving us the flexibility to mold everything from small medical components to large industrial housings. Sussex IM is equipped to handle new product launches, reshored programs, and complex production needs—efficiently, reliably, and at scale.

Your Custom Injection Molding Partner

At Sussex IM, technical capabilities are just the beginning. We back every program with collaborative support, deep process knowledge, and integrated services that reduce lead times and support long-term growth.

Quality

Our team is trained to meet strict internal and customer-defined standards. Every part is measured against detailed criteria for performance, appearance, and dimensional accuracy.

Reliability

With a 99.6% OTIF rate, we consistently deliver the right parts, on time and in full.

Automation

We engineer and maintain our own automation systems tailored to your part geometry, volumes, and handling requirements.

Full-Service Injection Molding Capabilities

Our capabilities go beyond molding. Sussex IM supports complex builds, downstream operations, and decorative processes all on site.

Complex plastic parts and assemblies
Insert molding and overmolding
Two-shot plastic injection molding and multi-shot molding
In-mold labeling and plastic part decoration
Processing of 100+ engineered injection molding plastics

Sonic and hot plate welding
Custom EOAT for insert molding solutions
Part handling and sleeving
Heat shrinking and hot melt dispensing
PCBA and kitting services
Temperature testing and documentation
4-axis and 6-axis robotics
Small parts assembly
Post-molding drilling and machining
Laser engraving
Auto part install verification
RFID overmolding and tag testing

We maintain a large fleet of molding machines to support flexibility, speed, and multi-cavity runs: 25T, 50T, 85T, 120T, 135T, 170T, 220T, 230T, 300T, 340T, 400T, 500T, 600T, and 725T.

Material Expertise for Real-World Performance

We’ve processed more than 100 engineered thermoplastics and offer detailed support during injection molding material selection. Every decision is backed by real-world testing, not guesswork.

Commodity Resins:

Polypropylene
ABS
High Impact Polystyrene (HIPS)
Polycarbonate
SAN
Nylon
Polyethylene

Specialized Resins:

PBT
Acetal
TPE
PETG
PMMA (Acrylic)

Silo Resin Storage:

To support high-volume programs, Sussex IM maintains six silos for bulk storage of ABS, polypropylene, and polystyrene, improving material consistency and operational efficiency.

One Injection Molding Company. Many Ways to Support You.

From prototype plastic injection molding to full-scale production and fulfillment, Sussex IM brings everything together under one roof. Fewer handoffs. More control. Better results.

Let’s talk about how we can support your next project.

Injection Molding