High Efficiency Automation for Injection Molding, Hybrid Components & Complex Plastics Manufacturing
Injection molding is a versatile manufacturing process used to produce high-volume plastic parts by injecting molten material into a precision-engineered mold. It is the most common method for modern plastic production due to its exceptional repeatability, speed, and cost-effectiveness at scale.
Robotics in injection molding automate critical production stages, primarily aimed at improving efficiency, consistency, and safety. Key applications range from initial material handling to secondary post-processing tasks, offering substantial measurable benefits such as up to a 30% reduction in scrap and 30% faster cycle times.
One of the most essential applications where robots quickly extract finished parts from the mold after cooling to prevent damage and maintain standardized cycle times.
Precision robots place metal pins, bushings, or wires into the mold before injection, ensuring exact placement and reducing rejects compared to manual loading.
Equipped with vision systems and sensors, robots perform real-time checks for surface flaws, dimensional inaccuracies (down to +/- .001 inches), and part orientation.
Robots handle post-molding tasks such as degating (removing excess material), trimming flash, labeling, laser welding, and heat staking.
Automated systems organize finished parts for downstream logistics, including stacking and sorting for kits, which streamlines the supply chain.
For machine tending (side entry), handling, finishing & automated part extraction.
For safe human robot interaction in compact production/inspection cells.
Overhead/Platen mounted for efficient mold access and part removal.
Cycle Time Reduction and Stability: Automation can speed up production by up to 30%. While some robots may add to the mechanical cycle, they stabilize and standardize the time between cycles, making production highly repeatable and reliable.
Scrap and Waste Reduction: Robotic precision minimizes human error, leading to fewer defects. Studies indicate that companies can see a 25% to 30% reduction in scrap rates.
Continuous “Lights-Out” Production: Robots enable 24/7 operations without breaks or fatigue, maximizing machine utilization and allowing facilities to run unstaffed during off-hours.
Enhanced Safety: Automation removes human workers from high-risk tasks, such as removing parts from hot molds or handling heavy inserts, reducing repetitive motion injuries and exposure to hazards.
Improved Consistency and Quality: Unlike manual handling, robotic arms ensure every part is handled identically, resulting in tighter tolerances and uniform product quality across large-scale manufacturing runs.
Robots have transitioned from simple part-extractors to central “controllers” that manage the entire injection molding lifecycle. In modern plastics manufacturing, they are primarily used to stabilize cycle times, handle high-temperature materials safely, and perform secondary operations directly at the machine side.
Injection molding, thermoforming, foaming & extrusion
Material handling, trimming, deburring, grinding, polishing
Assembly, finishing, packaging & palletizing
Flexible collaborative robot applications
Our robots are designed to address complex process requirements, high mix production, and the stringent quality expectations of plastics users in automotive, medical, consumer products, electronics, and more.
Industry data shows consistent growth in robotics adoption across global plastics manufacturing, driven by efficiency goals, labor shortages, and sustainability requirements. Robots stabilize cycle times, improve precision, reduce scrap, and support 24/7 output.
Plastics manufacturers added 1,646 new robots in 2023, reflecting strong investment in process stability and automation driven ROI. Additionally, they purchase 3 and 5 axis gantries for automation, which likely doubles that total number.
An intelligently linked system delivering high output, precision, and reliability.
How a fully automated system handles complex connector production.
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At Yaskawa Motoman, customer satisfaction doesn’t end at installation—it’s just the beginning. Whether you need expert training, real-time technical support, quick access to parts and service, or an extensive knowledge base at your fingertips, we’re here to ensure your automation systems perform at their best. Our dedicated team is available 24/7, and our tools and resources are designed to keep your operations running smoothly. From self-service support to personalized assistance, we’re committed to your long-term success every step of the way.