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Large Part Injection Molding
Where Scale Meets Precision Manufacturing.
PSI's large part injection molding capabilities handle shot sizes up to 35 lbs on high-tonnage equipment — producing complex, one-piece structural components with the dimensional integrity and repeatability that demanding programs require.
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110+
presses on the floor
2,100 Tons
max press tonnage
35 lb
max shot size

Core Capabilties

Built big. Engineered right.

Large part injection molding delivers major advantages at scale — one-piece construction reduces assembly labor, improves structural integrity, and achieves lower per-unit cost in high-volume production. PSI brings the same engineering discipline to large parts that it applies across every molding program.

Production Scale & Efficiency
Shot sizes up to 35 lbs
PSI's large-format press capacity accommodates substantial shot sizes and oversized part envelopes — components that smaller shops simply can't run.
Automated robotics and end-of-arm tooling
In-house end-of-arm tooling and robotic part removal keep cycle times competitive and reduce the handling risk that comes with large, heavy molded parts.
Consistent quality at volume
In-process controls and SPC monitoring ensure large-part programs hold the same dimensional and cosmetic standards run after run — not just at program launch.
Process Versatility & Engineering Flexibility
One-piece construction
DFM analysis identifies opportunities to reduce wall thickness, optimize rib geometry, and select the right resin grade — keeping part weight and material cost in check without compromising strength.
Tight tolerances across large components
Dimensional control on large parts requires careful process management — thermal gradients, warpage, and shrinkage all behave differently at scale. PSI's process engineering accounts for all of it.
Quality, Performance & Lifecycle Value
Structural and load-bearing applications
Strong, rigid parts engineered for structural applications — housings, enclosures, frames, and covers where dimensional stability and long-term performance under load matter.
Consistent material properties throughout
Processing parameters are optimized to deliver consistent material properties across the full cross-section of large, complex parts — avoiding the voids, sinks, and residual stress that degrade structural performance.
Finishing and assembly under one roof
In-house painting, hydrographics, and assembly mean large structural parts can be finished and assembled at PSI — delivered complete, not just molded.
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Not sure which process is right?

Injection molding vs. structural foam vs. gas assist – we’ll help you choose what’s right.

Part size, wall thickness, surface requirements, and structural demands all factor into process selection for large components. Talk to our engineering team and we'll tell you which approach makes the most sense for your program.
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The PSI Difference

Partnership From Day One

From the first design conversation to final assembly, our team works alongside your team at every stage. Engineering, molding, decoration, and assembly all happen under one roof, with a single team accountable for quality, timing, and consistency from start to finish.

No handoffs to outside vendors. No gaps in communication. Just experienced people who know your part, understand your standards, and are invested in getting it right.

Less guesswork.

No surprises.

Better Outcomes.

PSI asks questions before  a tool is cut — what does this part need to do, where does it live, what can’t it fail at? Our engineers work alongside yours from day one, so the people building your parts are in lock step with the people who designed them. Good engineering shouldn’t feel complicated. It should just feel like it works.

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Mold Transfer capabilities

Already have tooling? Transferring to PSI is easier than you think.

PSI has a proven process for qualifying and transitioning molds from other suppliers — minimizing disruption to your program while improving the quality, service, and cost structure of your molded parts. Whether you’re reshoring, consolidating suppliers, or simply looking for a better partner, we make the move straightforward.

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