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January 5, 2026
Injection Molding is Quietly Becoming One of the Core Technologies Used by SpaceX for Starlink Hardware
Injection Molding is Quietly Becoming One of the Core Technologies Used by SpaceX for Starlink Hardware
SpaceX is preparing for one of its largest manufacturing expansions yet, and injection molding is quietly becoming one of the core technologies powering that growth. As Starlink adoption accelerates worldwide (now surpassing 9 million users), the company is scaling its U.S. production footprint to meet demand for millions of additional satellite internet kits.
At the heart of this expansion is SpaceX’s Bastrop, Texas, factory, which recently added another million square feet of manufacturing space. The site originally produced around 15,000 Starlink dishes per day. With the added capacity, SpaceX now reports more than 170,000 Starlink kits per week rolling out across its U.S. operations, roughly 9 million units per year.
A major part of that scale-up comes from deeper vertical integration in injection molding, alongside die‑casting, PCB fabrication, and PCBA assembly. By bringing more molding operations in‑house, SpaceX reduces reliance on external suppliers, shortens lead times, and gains tighter control over part quality for high‑volume plastic components used in Starlink terminals.
The company says the Bastrop site will double production again in 2026, signaling even greater investment in molded components as Starlink expands into new markets, including India. Higher output could also influence hardware pricing, especially as SpaceX continues to refine its designs and introduce new dish models.
With injection molding now embedded in its manufacturing strategy, SpaceX is positioning Starlink hardware to be produced faster, at larger scale, and with greater cost efficiency, all engineered and built in the United States. Learn more about this topic here.
At the heart of this expansion is SpaceX’s Bastrop, Texas, factory, which recently added another million square feet of manufacturing space. The site originally produced around 15,000 Starlink dishes per day. With the added capacity, SpaceX now reports more than 170,000 Starlink kits per week rolling out across its U.S. operations, roughly 9 million units per year.
A major part of that scale-up comes from deeper vertical integration in injection molding, alongside die‑casting, PCB fabrication, and PCBA assembly. By bringing more molding operations in‑house, SpaceX reduces reliance on external suppliers, shortens lead times, and gains tighter control over part quality for high‑volume plastic components used in Starlink terminals.
The company says the Bastrop site will double production again in 2026, signaling even greater investment in molded components as Starlink expands into new markets, including India. Higher output could also influence hardware pricing, especially as SpaceX continues to refine its designs and introduce new dish models.
With injection molding now embedded in its manufacturing strategy, SpaceX is positioning Starlink hardware to be produced faster, at larger scale, and with greater cost efficiency, all engineered and built in the United States. Learn more about this topic here.
January 17, 2026
ExxonMobil, Erema, Moxietec & Engel Advance Sustainable Manufacturing Through Recycled‑Content Foaming Technologies
ExxonMobil, Erema, Moxietec & Engel Advance Sustainable Manufacturing Through Recycled‑Content Foaming Technologies
Across the plastics industry, a multi‑company partnership is proving that recycled materials can achieve the performance levels modern applications demand. By combining advanced foaming methods with polymer enhancement, the collaboration is opening new possibilities for lightweight, durable, and environmentally responsible components.
A central element of this effort is the integration of high‑quality recycled feedstock. Erema’s recycling systems convert a mixed stream of polypropylene rigids and polyethylene film into uniform pellets, creating a reliable base material for further processing. These pellets are then used in Moxietec’s foam molding technology, which produces lightweight structural parts such as construction blocks.
Performance is further strengthened through ExxonMobil’s Vistamaxx performance polymers. Specific grades, including Vistamaxx 3020 and 6102, contribute measurable improvements in impact strength, helping foamed parts maintain durability even with high levels of recycled content. Engel complements this material innovation with molding systems designed to process foamed structures efficiently, enabling thick‑walled components that balance strength with resource savings.
One of the most significant technical achievements comes from Moxietec’s next‑generation PFA and additive package, which supports the formation of fine, consistent cell structures. This uniformity is essential for maintaining stiffness, dimensional stability, and weight reduction, (key requirements for industries seeking sustainable alternatives without compromising performance. Learn more about this topic here.
A central element of this effort is the integration of high‑quality recycled feedstock. Erema’s recycling systems convert a mixed stream of polypropylene rigids and polyethylene film into uniform pellets, creating a reliable base material for further processing. These pellets are then used in Moxietec’s foam molding technology, which produces lightweight structural parts such as construction blocks.
Performance is further strengthened through ExxonMobil’s Vistamaxx performance polymers. Specific grades, including Vistamaxx 3020 and 6102, contribute measurable improvements in impact strength, helping foamed parts maintain durability even with high levels of recycled content. Engel complements this material innovation with molding systems designed to process foamed structures efficiently, enabling thick‑walled components that balance strength with resource savings.
One of the most significant technical achievements comes from Moxietec’s next‑generation PFA and additive package, which supports the formation of fine, consistent cell structures. This uniformity is essential for maintaining stiffness, dimensional stability, and weight reduction, (key requirements for industries seeking sustainable alternatives without compromising performance. Learn more about this topic here.
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