Lotis Technologies is the injection molding powerhouse in the Vantage Plastics family of companies. The team specializes in precision injection molded dunnage, shipping trays, seat pallets, rack dunnage, stacking columns, and other returnable packaging components that protect high value automotive and industrial parts in transit.
Lotis runs multiple high pressure injection molding machines along with a dedicated low pressure structural foam press, which is ideal for larger, lightweight, and very rigid products such as pallets and heavy duty trays.
If you have ever wondered “how does injection molding work” or “how should I design parts for injection molding,” this guide is for you.
At its simplest, plastic injection molding is a repeatable cycle:
You can think of it like a waffle iron that closes, fills, cooks, and opens again, only with far more precise temperature control, pressure control, and tooling.
This basic melt → inject → cool → eject sequence underpins nearly every injection molding application, from a small clip on a wire harness to an entire seat pallet that carries seats into an automotive assembly plant.
A modern injection molding press at Lotis is built around two main units:
Within one production cycle, engineers break the process into tightly controlled phases.
Molten plastic is pushed forward by the screw and enters the mold through the sprue, runners, and gate. The goal is to fill 90 to 98 percent of the cavity at a controlled speed so the flow front is balanced and air can escape through vents.
Once the cavity is nearly full, the machine switches from velocity control to pressure control. A holding pressure is applied through the gate to “pack out” the part as it shrinks during cooling. This prevents voids, sinks, and short shots and is a key part of scientific molding practice.
The mold is crisscrossed with precision machined cooling channels. Water or oil flows through these channels to remove heat from the plastic until it is solid enough to keep its shape during ejection. Cooling can represent most of the total cycle time, so Lotis engineers work hard on tool design and process optimization to shorten this phase without sacrificing part quality.
When the part has cooled, the clamp opens and an ejection system pushes the part off the core. Ejector pins, sleeves, air blasts, or lifters may be used depending on the geometry. The mold then closes and the next shot begins.
This controlled cycle allows Lotis Technologies to produce thousands or even millions of identical components with tight tolerances and very low scrap rates.
For engineers and sourcing teams, the real value lies in how the process is controlled and tailored to each application. Lotis brings two key layers of expertise.
Scientific, or decoupled, molding is a methodology that uses data and cavity driven process windows rather than trial and error. The cavity is filled to a defined percentage at a set velocity, then the press transitions to optimized pack and hold pressures and times. The result is a robust “recipe” that produces consistent parts even when there are normal variations in material lot, ambient temperature, or machine behavior.
Benefits include:
For automotive and industrial customers, this consistency is what keeps lines running and packaging programs on schedule.
Lotis also specializes in structural foam injection molding, a low pressure process where a blowing agent creates a microcellular foam core inside a solid skin. This delivers:
When your program calls for big, tough components that are still light enough for ergonomic handling or automated systems, structural foam becomes a powerful option.
Design is where many programs are won or lost. Because Lotis is known for its design expertise, the team often engages early to help customers “design for molding” rather than trying to force a cast, machined, or fabricated concept into a mold.
Here are the fundamentals every engineer and buyer should understand.
Uneven wall thickness is one of the fastest ways to introduce sink marks, warpage, and long cycle times.
Uniform walls let the plastic flow and cool more evenly which keeps parts flatter and reduces residual internal stress.
Since parts are ejected off a steel core, they need draft so they can slide without scuffing.
Sharp inside corners act as stress concentrators and can trap material flow. Fillets and radii improve strength and flow while reducing the risk of cracking.
Ribs and bosses are critical in automotive trays, seat pallets, and rack dunnage where strength and stiffness are required without unnecessary weight.
When metal inserts are needed for threaded connections or wear surfaces, designers must consider proper wall stock around the insert and the right installation method, whether overmolding or post molded insertion.
Where the molten plastic enters the part and how it flows through the cavity are major design decisions.
Lotis engineers use flow simulation tools and their real world experience with dunnage, pallets, and trays to make decisions that balance appearance, strength, and mold complexity.
Good injection molded part design is always a three way conversation:
Because Lotis is focused on returnable packaging and durable components, programs often justify more sophisticated tooling that pays back through long life and reduced part damage in the field.
When you bring a project to Lotis Technologies, you are connecting with an integrated team that spans:
For automotive OEMs and Tier 1 suppliers in particular, Lotis understands how packaging fits into the entire supply chain. Solutions are engineered to:
If you are exploring or already using injection molded solutions, keep these points in mind:
When you are ready to talk through a new tray, pallet, or custom component, the Lotis team is ready to walk through your requirements, review your CAD, and show you how the injection molding process can be engineered around your program rather than the other way around.