--- title: Net Shape Molding canonical: https://www.pexco.com/capabilities/injection-molding/net-shape-molding/ --- [Injection Molding](https://www.pexco.com/capabilities/injection-molding/) -------------------------------------------------------------------------- Net Shape Molding ================= Where Ideas Take Shape ---------------------- Net shape molding produces injection-molded components that achieve final dimensional specifications directly out of the mold, eliminating or minimizing secondary machining operations. This approach preserves critical surface integrity, reduces manufacturing costs, and improves component performance by maintaining resin-rich surfaces free from micro-cracks and fiber exposure caused by machining. Pexco's proprietary iterative tool design process integrates industrial CT scanning with precision measurements to achieve tolerances as tight as ±0.0003 inches on complex geometries molded from ultra-high-performance materials like PEEK, PAI (Torlon), and fluoropolymers. ![](https://www.pexco.com/wp-content/uploads/2025/12/injection-molded-components-3-1000x1000.jpg) Proprietary Iterative Tool Design --------------------------------- Pexco has developed a systematic approach to net shape molding that combines advanced software tools with iterative physical testing and tool modification: #### Mold flow and finite element analysis to predict material behavior and optimize gating, cooling, and part geometry #### Initial tool design incorporating decades of processing knowledge for high-performance thermoplastics, accounting for material shrinkage, thermal expansion, and process-induced stresses #### CT scanning measurement integrating CT data with CAD/CAM software to identify precise areas requiring tool modification #### True form sizing technology integrating CT data with CAD/CAM software to identify precise areas requiring tool modification #### Iterative refinement cycles continuing until parts consistently meet all dimensional specifications directly from the mold --- This approach allows our engineering team to make highly targeted tool modifications rather than relying on traditional trial-and-error methods. For critical sealing surfaces, bearing interfaces, and precision mating features, this level of dimensional control enables us to achieve tolerances that would be impossible through conventional molding followed by secondary machining. See \[Industrial CT Scanning & Metrology\] for detailed capabilities. Insert Molding Integration -------------------------- Net shape molding techniques extend to insert molding applications where metal components, sensors, or other substrates integrate into the molded part. Our proprietary tooling and thermal management systems ensure proper polymer flow around insert features while maintaining dimensional stability of both the insert and surrounding geometry. For comprehensive overmolding capabilities including delicate insert handling, multi-material combinations, and robotic placement systems, see [Overmolding & Insert Molding](https://www.pexco.com/capabilities/injection-molding/overmolding-insert-molding/). Design for Manufacturability ---------------------------- Pexco's engineering team provides comprehensive design support for net shape molding from concept through production, including mold flow analysis, finite element analysis, and design for manufacturability reviews. We optimize part geometries with appropriate draft angles, wall thickness transitions, and feature locations that support consistent dimensional control. Our 6 in-house tool and die centers handle mold design, fabrication, and rapid modifications throughout the development process. See [Design Engineering Services](https://www.pexco.com/capabilities/advanced-plastic-engineering/design-engineering-services/) and [In-House Tooling & Die Manufacturing](https://www.pexco.com/capabilities/advanced-plastic-engineering/in-house-tooling-die-manufacturing/) for complete capabilities. Materials & Resins ---------------------- Pexco's net shape molding capabilities support the most demanding high-performance thermoplastics: #### Imidized Polymers PAI (Torlon), PBI - For extreme temperature and wear resistance applications #### Advanced Fluoropolymers FEP, PFA, HP PFA, UHP PFA, PVDF, ETFE - For chemical resistance and ultra-high purity requirements #### Advanced Thermoplastics PEEK, PEI (Ultem), PSU (Polysulfone), PPS (Ryton), EXTEM - For structural components requiring high strength and thermal stability #### Custom & Filled Materials Glass-filled, carbon-filled, mineral-filled compounds optimized for dimensional stability ![](https://www.pexco.com/wp-content/uploads/2025/11/AdobeStock_619634878-1-1000x1000.jpeg) Why Choose Pexco? ----------------- Tolerances as tight as ±0.0003 inches on net shape molded components --- Proprietary iterative tool design process with CT scanning verification --- Up to 1.2 million dimensional measurements per part for tool refinement --- Eliminates secondary machining while improving component performance --- Preserves resin-rich surfaces for enhanced strength and sealing capabilities 6 in-house tool and die centers for rapid tool modifications --- Advanced insert molding for complex assemblies --- ISO 9001:2015 certified, ITAR registered --- Full design support from concept through production Related Capabilities -------------------- Get Started ----------- Contact Pexco's net shape molding team to discuss how our proprietary iterative tool design process can eliminate secondary operations and improve your component performance. 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