Large-Part Injection Moulding
Moulding a 270mm diameter disc with 1.5mm wall thickness requires expertise in flow dynamics, gate placement, and warpage control. The frisbee project showcases our capability to produce large-surface, thin-wall parts with excellent flatness and consistent flex characteristics.
The aerodynamic profile demands precise replication of the rim geometry, which directly affects flight stability. Our mould achieves surface profile accuracy of ±0.1mm across the 270mm span.
Material: Impact-Modified Polypropylene
We use Moplen EP310K (LyondellBasell), a nucleated impact-modified PP copolymer that provides the ideal combination of stiffness, impact resistance, and flexibility for disc sports. The material withstands repeated impacts on hard surfaces without cracking or permanent deformation.
PP was chosen over ABS or PS for its superior fatigue resistance (>1 million flex cycles), lower density (0.90 g/cm³ for a lighter disc), and food-contact safety for promotional items.
Manufacturing Process
The single-cavity mould uses a 3-point gate system with sequential valve gate control to prevent flow hesitation marks on the disc surface. Injection profiling progressively fills the disc from centre to rim, achieving balanced orientation for consistent flex.
Cycle time is 35 seconds on a 300-ton press. Automatic part removal with a vacuum gripper preserves the hot part geometry during ejection. The disc is held in a cooling fixture for 60 seconds to prevent warpage.
Customisation Options
Frisbees are available in any colour, including multi-colour (overmoulded) and glow-in-the-dark variants. Branding options: in-mould labelling (IML), pad printing (up to 6 colours), and digital printing (photographic quality).
Quality Assurance
ISO 9001:2015 certified. Weight tolerance: ±2g (target 175g, competition standard). Flatness tolerance: <0.5mm across diameter. 100% visual inspection for gate vestige, sink marks, and colour consistency.
Frequently Asked Questions
Can you produce competition-standard disc golf discs?
Yes, we produce discs meeting PDGA specifications. Different rim profiles (driver, midrange, putter) require separate moulds but use the same production cell.
What is the minimum order for custom-branded frisbees?
Minimum 1,000 pieces for pad printing on stock discs. Custom moulds for unique shapes start at 5,000 pieces including mould amortization.
Technical Specifications
Material: PP Moplen EP310K | Diameter: 270mm | Thickness: 1.5mm rim, 2.0mm centre | Weight: 175g ±2g | Mould: single-cavity, 3-point valve gate | Cycle: 35s | Press: 300 tons