Primary process: Injection Molding. The full route, materials, tolerances and design tips for a light switch, with an indicative cost.
Injection MoldingPrimary process
PolymerFamily
7Route steps
+/-0.05mmTypical tol.
A light switch is primarily made by Injection Molding. Plastic injection moulding injects molten polymer into a cooled steel mould under pressure; it solidifies and ejects as a finished part in seconds. Below is the full route to make a light switch, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How a light switch is made
The usual route, raw material to finished part. The amber step is where the light switch gets its basic shape.
Material
Select the polymer grade and colourant for the light switch and dry the pellets.
Tooling
Cut the steel or aluminium mould that forms the light switch.
Injection Molding
Melt and form the polymer in the cavity to make the light switch.
Tooling High (steel mold) Tolerance ±0.05 to 0.2mm Lead 4 to 8 weeks
De-gate and trim
Remove the runners, gates and flash.
Secondary
Where the light switch needs them, add inserts, printed graphics or machined details.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Assembly
Where the light switch joins other parts, snap-fit, weld or bond it into the finished product.
Tooling Low Tolerance good Lead immediate
Inspection
Check fit, finish and any functional dimensions.
Need the real cost for a light switch? The free route above is yours. Unlock the full dossier to quote and source it.
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials for a light switch
Grade
Why it suits this
ABS
Tough, cheap, easy
Polypropylene (PP)
Living hinges, chemical
Glass-filled nylon (PA-GF)
Stiff, strong
Design
Design tips
General pointers. The full design-for-manufacturing list for a light switch is in the dossier.
Thick or uneven walls.Even them, core out thick bosses.
No draft.Add >=1 deg draft.
Cost
What a light switch should cost
The qty-1 figure is really the mold (2k to 50k+ USD) amortised; above ~5k parts it is pennies of resin.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for a light switch at your volume, in your currency, are in the dossier.
MODEL EST.
$1840 to 3130per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on a light switch and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
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A light switch is primarily made by injection molding. The route is: Material; Tooling; Injection Molding; De-gate and trim; Secondary; Assembly; Inspection.
What does a light switch cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $1840 to 3130 per part at 1 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is a light switch made from?
Common choices are ABS; Polypropylene (PP); Glass-filled nylon (PA-GF).
What is the main process for a light switch?
Injection Molding. High-volume plastic parts of almost any shape, from housings to medical devices.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
