Totally agree with you on the character casting can bring—those bronze handles sound amazing, btw. I've seen similar handmade hardware go for crazy prices online, so you're probably saving money and getting something way cooler. But yeah, injection molding definitely wins if you're doing a bigger batch. I tried casting some decorative knobs once, and after sanding knob number 12, I was seriously questioning my life choices...
"I tried casting some decorative knobs once, and after sanding knob number 12, I was seriously questioning my life choices..."
Haha, I feel your pain there. I've been weighing these two methods myself lately, and honestly, the sanding and finishing time is something people often underestimate. Sure, casting gives you that unique, handcrafted vibe—but at what cost in terms of hours spent hunched over sandpaper?
Injection molding seems like the clear winner if you're scaling up production, but I'm curious—has anyone done a detailed cost breakdown comparing smaller batches? Like, at what exact point does injection molding become more economical than casting? I've seen some DIYers online who swear by silicone molds for small runs because they're reusable and relatively cheap. But then again, how many pulls can you realistically get before the mold quality starts to degrade?
It's definitely a balancing act between upfront costs, labor intensity, and the final aesthetic you're aiming for...
"Sure, casting gives you that unique, handcrafted vibe—but at what cost in terms of hours spent hunched over sandpaper?"
Exactly this. I did a small run of resin knobs last summer thinking I'd save money, but after factoring in sanding, finishing, and my sanity (lol), injection molding suddenly didn't sound so pricey. Silicone molds are great for 10-20 pulls, but after that, the details get fuzzy. For me, anything past that and injection molding starts looking pretty attractive, even with the upfront costs.
I feel your pain on the sanding front—last year I got ambitious and decided to cast custom handles for a furniture project. Thought it'd be quick and easy... famous last words, right? After hours of sanding and re-sanding (and inhaling way too much resin dust), I was seriously questioning my life choices. The first few pulls were crisp, but like you said, after about a dozen or so, the silicone molds started losing detail fast. By the 20th handle, it was like trying to copy a photocopy of a photocopy—just blurry and disappointing.
Injection molding definitely has its perks if you're scaling up production. But one thing that keeps me hesitant is the environmental angle. I've been trying to reduce my footprint lately, and injection molding setups often come with lots of upfront tooling and waste material. Plus, depending on the plastic used, recycling can be tricky. On the flip side, casting lets me experiment with eco-friendly resins (though honestly, some of those can be hit-or-miss in terms of durability).
Have you (or anyone else here) tried injection molding with recycled or bio-based plastics? I'd love to hear if that's becoming more accessible or practical these days. Seems like it could be a decent compromise between efficiency and sustainability...
I ran into a similar issue when I tried injection molding with recycled plastics a while back. The idea sounded great on paper, but sourcing consistent-quality recycled material was trickier than expected. Some batches flowed perfectly, others clogged the molds or came out brittle. Bio-based plastics were more reliable, but pricier and still limited in variety. It's definitely doable, just be prepared for some trial-and-error and extra tweaking to your setup...
