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Home / Injection Molding Trends in 2025: AI and Smart Production Workflows

Injection Molding Trends in 2025: AI and Smart Production Workflows

2025/08/22 By le zhan

Injection Molding Trends in 2025

In 2025, injection molding will be an intelligent, data-driven manufacturing technology that combines sensors, algorithms, and proven electric drives to achieve scalable, repeatable quality. Topstar’s independently developed all electric injection molding machine controller has moved from the lab to customer production lines. Through deep process optimization driven by proprietary algorithms, we have observed significant improvements in molding consistency and production efficiency in pilot plants. In practice, the controller, combined with precision servo systems and closed-loop sensing technology, has reduced cycle-to-cycle variability and improved the molding yield of quick-connect automotive connectors used in AI servers and for partners such as Xiaomi’s automotive supply chain.

Topstar has also opened a new facility and is committed to providing comprehensive, innovative factory solutions to global manufacturers. In 2025 and beyond, our goal is to embed AI, advanced controllers, and control servo systems into production, transforming scientific advances into operational advantages on the factory floor.

Injection Molding and AI: Process Optimization and Closed-Loop Control

AI has moved from pilot projects to core process control in injection molding. Modern AI no longer serves as a separate analytical layer; it is directly integrated with injection molding machines and controllers to achieve closed-loop optimization. In practice, this means leveraging high-frequency sensor data to train models to predict defects, recommend parameter adjustments, or autonomously adjust setpoints mid-cycle.

This makes the production line adaptive. For example, when the cavity pressure profile drifts due to material batch variations or ambient temperature fluctuations, the AI ​​controller can adjust the injection speed or hold time within the same cycle window to prevent undershot or flashing. In addition to immediate quality improvements, AI capabilities also support predictive analytics. By analysing long-term trends, the system can identify servo current, heater resistance, or cycle anomalies before they lead to downtime. For businesses, this means higher production output while maintaining consistent quality and lowering operating costs.

Electric Servo Drives and Precision Motion Control

Electric injection molding machines have become the benchmark for precision and energy efficiency. In injection molding, they offer finer motion control, faster response times, and more repeatable injection processes than hydraulic systems. Topstar’s fully electric solution combines servo motors, high-resolution encoders, and a proprietary control system to manage screw/platen motion, dosing, and multi-axis mold movements with deterministic timing.

Servo drive control’s dynamic control features, such as active vibration suppression and motion trajectory jerk limiting, reduce mechanical stress on the mold and ejector. This enables all-electric injection moulding machines to achieve shot-to-shot consistency in micro-features, such as contact cavities and thin ribs, in connector moulding, whether for AI server companies or automotive quick connectors.

all electric injection molding machine 7-7

Precision Solutions for AI Server Companies and the Automotive Supply Chain

AI servers require high-density, heat-resistant connectors that can be assembled reliably at high speeds. Automotive platforms demand connectors that withstand vibration, thermal cycling, and contamination. Our electric injection molding machines, coupled with AI-enhanced controllers, meet the requirements of both sectors by achieving tight tolerance control and repeatable micro-feature molding.

All electric injection molding machines offer cavity pressure balancing control for multi-cavity molds, precise control of holding pressure variations to control flash in thin-walled sections, and micro-injection control to replicate thin ribs without sink marks. For AI server companies, signal integrity depends on precise dielectric positioning; these control measures maintain the impedance profile during the overmolding process. In the automotive sector, we support Xiaomi’s automotive supply chain with precision injection molding solutions for high-reliability quick-connect connectors.

Intelligent Injection Molding Production Workflow

From traditional manufacturing to today’s intelligent manufacturing, the injection molding production workflow integrates machines, molds, material logistics, and quality inspection into a unified system. With the digital twin playing a central role, simulations of the injection molding machine, mold, and process parameters can be run in parallel, allowing changes to be validated before they reach the actual production line.

In the actual workflow, a synchronized data pipeline provides the digital twin with real-time telemetry data: melt temperature history, cavity pressure characteristics, in-mold sensor arrays, and machine kinematics. The digital twin then tests “what-if” scenarios, such as switching resins, adjusting the holding pressure profile, or changing the cycle time, to predict outcomes and recommend the least disruptive optimized path. This allows for rapid recipe changes and minimizes downtime.

Providing intelligent, integrated solutions for the global manufacturing industry

In July 2025, Topstar’s global R&D headquarters officially opened and commenced operations, integrating manufacturing, international sales, and support services to serve its global customers better. Our R&D centre features an intelligent laboratory designed to evaluate artificial intelligence algorithms, sensor fusion methods, and human-machine interaction approaches, thereby making controllers more intuitive and autonomous. The Environmental Reliability Laboratory simulates thermal cycling, humidity exposure, and chemical resistance. The EMC Laboratory verifies that machines and control systems do not damage sensitive electronic components during the injection molding process and comply with regulatory limits. We focus on embodied intelligence, researching key technologies such as intelligent perception, decision-making algorithms, and human-machine interaction. Leveraging AI, controllers, and control servos, we enable our technological achievements to be operational in the production lines of diverse customers worldwide.

Providing intelligent, integrated solutions for the global manufacturing industry

Integrating AI and Smart Manufacturing into Injection Molding

By 2025 and beyond, the injection molding process will transform from a process-centric approach to an integrated, AI-enabled manufacturing technology. Electric injection molding machines, tightly integrated with intelligent controllers and high-bandwidth servos, deliver the precision required for advanced connectors, electronics, and automotive parts. Intelligent workflows and laboratory-supported validation shorten time to market and reduce the risk of scale-up failure. Topstar is also accelerating its global expansion, leveraging its core technologies to bring more innovative achievements to the world and contribute to the global upgrade of smart manufacturing.

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