Plastic Injection Molding

All molds are built to SPI standards with most being Class 101.

Guaranteed for 1,000,000 or more cycles
- (one customer calls it a Bazillion cycle mold)
Replaceable components

Hardened mold base with hard mold surfaces
Guided ejection
Wear plates for slides
Parting line locks

Corrosion resistant for cooling standards

Molds and Configurations

We have experience with many types of molds and configurations including:

Hot runner systems
Runnerless dies

Threaded parts design
Insert configuration

Collapsible cores

A key factor in mold design is understanding the application of the product, material to be used, and the part size. Our part experience with molding, from the smallest part weighing a fraction of a gram to large parts weighing one pound up to 14" in diameter, has enhanced our capabilities.

Resin Experience

We have resin experience with both engineering and commodity resins including thermoplastic elastomers (including additives) has given us the necessary knowledge needed in the design of the molds.

Some of the resins for which molds have been used include:

Thermoplastics elastomers
Kraton, Dynaflex, Santoprene, Marlex
EMI Shielding material and fillers
Carbon filled
Stainless fibers
Static controlled
Clear and transparent Polycarbonate
Acrylic

Conductive
High temp conductive and shielded such as
- Ryton
- Nylon 6/6 with and without glass fibers
- Valox
- Peek

Thermoset SBR

Scientific Injection Molding (SIM)

We use a highly technical scientific approach in the injection molding process which optimizes an injection molding process . Its use allows us to eliminate waste and reduce costs.

Quality Dimensional Experience

We have strict adherence to the highest quality standards. Criticals 2.00 Cpk, Majors 1.33 Cpk, Minors 1.00Cpk are what we consistently achieve-on all cavities. Combined with using with statistical control procedures, we capture dimensional and attribute data on parts.

Some of the programs we use are:

PPAP (Production Part Approval Process)
Part data collection and retention by cavity
Capability Studies
Failure Mode Analysis
Automated and mechanical measurement systems
Data available on Zip disks, electronically or on paper

100% inspection on each cavity
First and last shot retention for one year
Quality plans per product
Certifications
Statistical process controls
Final audits prior to shipment
Design of Experiments
Gage R&R studies

Solutions have been developed for molding parts weighing less than .001g and tolerances as tight as .0001in. We help your market to share in the micro markets.

Risk Control Through Statistical Process Control (SPC)

Our focus is on monitoring four critical elements during the molding process:

Cushion
Fill time

Screw recovery time

Melt temperatures

By the use of these effective process control elements we assess the stability and repeatability of the molding process. This in turn allows the process to be robust to variation in equipment, raw material and their process inputs to give a consistently performing product and allows it to be managed for continuing improvement.