Fathom offers the latest injection molding technology, producing high-quality polystyrene (PS) parts for its customers. Fathom’s experts are ready to help you with your time-sensitive, high precision, highly complex, or short production run-related projects. Injection molding is just one of many manufacturing technologies offered by Fathom. Get started today.
Polystyrene is a popular raw material that can be used for various products. PS is made through a distillation of hydrocarbon fuels mixed with catalysts to form plastic. A synthetic polymer, PS is non-toxic and odorless. Polystyrene is easy to form and lightweight. Common applications of polystyrene include food packaging, toys, utensils, packing material, single-use cups, auto parts, etc. Polystyrene is flammable and, when burned, emits water and CO2.
Polystyrene (PS) is used for injection molding for multiple reasons. Polystyrene is durable, recyclable, and provides good insulation. PS is resistant to both bacteria and moisture. A lightweight material, it is odorless and nontoxic. Polystyrene is a cost-effective and widely available material that can be used in many different industries. Polystyrene has a high melting point and requires a high energy input when injection molding. PS has an excellent shrinkage rate of around 0.5%, which is considerably low compared to other plastics. Polystyrene can be injection molded into solid or foam parts.
There are three main categories of polystyrene: plastic, film, and foam. Polystyrene film is stretchable and is vacuum formed for packaging. The foam form of polystyrene includes expanded polystyrene (EPS) and extruded polystyrene (XPS). EPS is used to produce packing peanuts or Styrofoam. XPS has a higher density and is sometimes used to build models. The homopolymer plastic PS is brittle and can be combined with other materials to add impact resistance. General-purpose polystyrene (GPPS) is clear, while high-impact polystyrene (HIPS) is opaque. In its plastic form, PS is used to make everything from Petri dishes to instrument panels.
Following injection molding, the part is moved to the finishing process. The finishing stage can change a part’s appearance or enhance its physical properties. Here are some of the finishing processes offered by Fathom.
| SURFACE FINISH | GUIDE | TYPICAL APPLICATIONS |
|---|---|---|
| Standard No Machine Mark | Tool Marks Removed | Low Cosmetic |
| SPI-C1 | 600 Stone | Low Polish Parts |
| SPI-B1 | 600 Grit Paper | Medium Polish Parts |
| SPI-A2 | Grade #6 Diamond | High Polish Parts |
| SPI-A1 | Grade #3 | Lens or Mirror |
| IM-1 Light Bead Blast | Need 1 Degree Draft Angle | |
| IM-2 Medium Bead Blast | Need 1.5 Degree Draft Angle | |
| IM-3 Heavy Bead Blast | Need 3 Degree Draft Angle |
Fathom’s manufacturing technologies include injection molding and hybridized services that leverage 3D printing. Do you need injection molding as part of your complex project? Fathom can help. In a recent case study, Fathom delivered over 20,000 parts in 27 days, using 55+ tools, including multiple injection molding services:
A customer came to Fathom with a complex project that spanned the technologies and processes of rapid production—and needed it done fast. Fathom delivered.
55+ Tools to Injection
Mold 15,000 Parts
First Article in 2 Weeks
3,000+ 3D
Printed Parts
2,000+ Metal
Fabricated Parts
3D Printing / Additive Manufacturing—PolyJet, SLS, MJF.
DFM Analysis + CAD Mods.
CNC Machining. Laser Cutting.
Stamping. Die Cutting. Post-Opp Drilling.
24-hour Turnaround Urethane Casting.
Injection + Compression Molding.
Model Finishing. Insert Assembly.
Advanced Project Management.
A: Yes, Fathom offers injection molding services.
A: Injection molding is a manufacturing process commonly used for plastic parts. During injection molding, molten plastic is injected into a two-part mold using high pressure. Once the part has cooled inside the mold, it is ejected. The part may or may not require a secondary finish.
A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Polystyrene is suitable for injection molding.
A: Polystyrene is used to make many different products, including disposable cups, utensils, packing peanuts, food packaging, toys, etc.
A: Yes, PS is short for polystyrene.
A: Polystyrene (PS) can be liquified and has a low shrinkage rate, making it an ideal material for injection molding. PS can be reheated, cooled, and heated again without degradation, which helps to reduce material waste.
Are you ready for a quote or to calculate costs on a polystyrene injection molding project? Send Fathom the details of your design through the SmartQuote application for a fast quote.
