Design Assistance

With so many choices available, selecting the right materials for your application can be confusing. We rely on our experience to assist you in selecting the right material for your applications at the most economical prices. Additionally, we can provide recommendations for your designs to reduce molding and secondary service costs.

• Feasibility for Molding

• Design for Manufacturing

• Resin Selection

• Design for Assembly

• Thick and thin wall capability

• Insert molding

• Decorating

Prototyping

Quality prototype development is key to being a market leader in any industry. Our prototype capability provides greater flexibility to explore product development alternatives. We provide the prototype capability for quick to market products.

Mold Development

Getting it right with the mold design pays off with performance and durability in production. We review the feasibility for molding and perform a Flow Simulation Analysis to ensure mold designs meet our high standards. Using the expertise of domestic and low-cost off-shore mold builders we can ensure our customers receive high-quality and durable molds.

Injection Molding

Injection molding is ideal for producing high volumes of the same object. Granular plastic (resin) is slowly fed into a heated barrel. As the resin moves forward by a screw-type plunger, the plastic is forced into a heated chamber, where it is melted. As the plunger advances, the melted plastic is forced through a nozzle that rests against the mold, allowing it to enter the mold cavity through a gate and runner system. The mold remains cold so the plastic solidifies almost as soon as the mold is filled.

The molding cycle begins when the mold closes, followed by the injection of the polymer into the mold cavity. Once the cavity is filled, a holding pressure is maintained to compensate for material shrinkage. Once this is done, the screw turns, feeding the next shot to the front screw causing the screw to retract as the next shot is prepared. Once the part is sufficiently cool, the mold opens and the part is ejected.

Presses are rated by tonnage, which expresses the amount of clamping force that the machine can exert. This force keeps the mold closed during the injection process. Tonnage can vary from less than 5 tons to 6,000 tons. The projected area of the part being molded determines the clamp force required. If the plastic material is stiff, it will require more injection pressure to fill the mold, thus more clamp tonnage to hold the mold closed. The material used and the size of the part can also determine the required force. Larger parts require higher clamping force provided by a higher tonnage press.

Material Selection Guide

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