Injection Moulding — Production-Volume Plastic Parts, Australia
From 100-part bridge runs to multi-million unit production programmes, Forge Labs manages the full injection moulding workflow — DFM review, tooling, T1 sampling, production and freight — under one Sydney-based engineer.
Typical projects start from $500+ · Engineering & business enquiries welcome · Upload CAD, STEP & STL files for review
Manufactured in
Sydney, Australia · Quality-checked on every job
Why Forge Labs
Why brands choose Forge Labs for injection moulding
A local project manager, transparent tooling pricing and the right tool for your volume.
100 to 1,000,000 Parts
From bridge-tooling runs of 100 parts to long-cycle production volumes — quoted under one local point of contact.
Engineering Polymers
ABS, PC, PP, PE, Nylon, PC-ABS, TPU, Glass-Filled Nylon, ASA and food-contact grades — supplied by tier-one chemical companies.
Aluminium & Steel Tooling
Aluminium tooling for fast prototype-to-bridge runs; hardened P20 / H13 steel tooling for high-cycle production.
Local Project Management
Your project is run by a Sydney-based engineer — design review, T1 sampling, ECN management, the lot.
Sampling & Approval
T1 (first-shot) parts are dimensionally inspected and approved by you before any production run begins.
Our Workflow
From CAD to production-moulded parts
DFM review
Send us your part CAD and target volume. We'll review draft, gating, wall thickness, undercuts and material — and quote tooling + per-part price.
Tooling manufacture
Aluminium tools in 3–5 weeks, hardened steel in 6–10 weeks. We supply CAD of the tool for your records.
T1 sampling
First-shot parts are inspected, photographed and shipped to you for approval before production. Tooling adjustments are made if needed.
Production & dispatch
Approved tooling runs production batches with packaging, labelling and freight handled to your spec.
What we deliver
Injection moulding done with engineering rigour
DFM-first · Aluminium or steel tooling · T1 approval before production
Injection moulding has the lowest per-part cost of any plastic manufacturing process — but only if the tool is right. Forge Labs spends as much time on design-for-mouldability review as we do on the tooling itself, because the cost of an avoidable tooling change is always larger than the cost of catching the issue in CAD. Every tool we commission goes through T1 sampling and your written approval before a single production part is run.
- Engineering DFM review before tooling is cut — draft, gating, wall, undercut
- Aluminium bridge tooling for 100–10,000 parts; hardened steel for 10k–1M+
- Over-moulding (TPU on ABS, TPE on PP) and insert moulding (brass, magnet, PCB)
- 20+ engineering polymers in stock from tier-one chemical suppliers
- T1 sample, dimensional report and approval gate before any production run
- Packaging, kitting, labelling and freight under one PO
Materials
Polymers we mould every week
From everyday ABS housings to food-contact PP and over-moulded TPU grips.
ABS
GeneralTough, paintable, plateable — the most-moulded plastic in the world. Default for housings, consumer electronics and toys.
Polypropylene (PP)
FlexibleLiving-hinge capable, chemically resistant, food-contact safe. Caps, closures, fluid containers and kitchen products.
Polycarbonate (PC)
OpticalOptically clear and impact resistant. Used for safety lenses, light covers, medical housings and transparent enclosures.
PC-ABS
HybridBlends PC heat resistance with ABS toughness. Common for automotive interior trims and ruggedised electronics.
Nylon (PA6, PA66, GF)
EngineeringTough, wear-resistant engineering nylon. Glass-filled variants for stiffness — gears, bearings, structural parts.
TPU / TPE
Soft-touchFlexible elastomers for over-moulded grips, gaskets, seals and soft-touch consumer product features.
ASA
OutdoorUV-stable thermoplastic for outdoor and automotive exterior parts — won't yellow like ABS.
Food-Contact Grades
RegulatedFDA/EFSA-listed PP, PE and PET grades for food-contact, cosmetics and pharma packaging.
Industries we serve
What we mould
Production-quantity plastic parts for Australian brands across consumer, medical, automotive and industrial sectors.
Consumer Products
Retail-ready housings, packaging, closures and components for Kickstarter graduates and established consumer brands.
Medical Components
Sterile-pack ready injection-moulded housings, fluid handling components and disposable instrument bodies.
Automotive Interior & Aftermarket
Trim panels, clips, fasteners, vent housings, sensor enclosures and dealer-fit accessory parts.
Electronics Enclosures
Cosmetic-grade housings, snap-fit lids, panel mounts and EMI-shielded compartments for production electronics.
Industrial Components
Production-quantity covers, knobs, handles and equipment housings for OEM manufacturing programs.
Lab & Pharma
Sample containers, fluid handling, single-use lab consumables and pharmaceutical-grade packaging.
Showcase
Recent moulding work
T1 sample parts straight off a new aluminium production tool.
Low-volume injection run for an Australian consumer brand.
Injection mould tool — cavity side, ready for first-shot sampling.
FAQ
Frequently asked questions
Ready to start your project?
Upload your file or send a quick brief — most quotes come back within 4 working hours, with parts dispatched Australia-wide from our Sydney workshops.