Services
Design it right. Mold it right. Keep it running.
Most of our work is new product design, part optimization and injection mold construction. Every service draws on the same advantage: we also run a molding plant, so our advice reflects what happens on the press, for the molder and for the OEM.
Product design and design for manufacturing
You have a concept, a prototype or a drawing, and need a part that molds well and lasts.
We start with your requirements: tolerances, assembly, environment, service life, electrical and UV criteria. Then a materials review, a design review backed by simulation, and a manufacturing plan with cycle times and costs.
You receive
- Production-ready CAD (Onshape, SolidWorks)
- Material recommendation with rationale
- DFM review and simulation results
- Cost analysis at your volume breaks
Mold design and construction
You need tooling that runs from the first shot and grows with your volumes.
Hot runner, multi-cavity, collapsible and unscrewing cores, hand-load inserts, and compression molds for phenolics and other thermosets. We design modular molds with interchangeable inserts for product families, and plan bridge tooling that can take more cavities later.
You receive
- Mold design, in-house or through our partners
- Build managed with domestic or overseas toolmakers
- First-article sampling and measurement
Process development
Scrap is high, cycles are long, or the process will not hold.
A scientific molding approach on our presses or yours. We baseline the existing process, auxiliaries, cooling and heaters, then run an efficient DOE to set a robust window for ongoing production.
You receive
- Documented process window and setup sheets
- DOE data behind every setting
- IQ/OQ/PQ validation support when needed
Failure analysis and root cause
Parts are cracking, warping or failing in the field.
We collect the evidence, direct testing through our regional lab network (FTIR, DSC, TGA, SEM, GC/MS, mechanical) and interpret it ourselves. Then we change the material, design or process to remove the cause.
You receive
- Evidence-based root-cause report
- Corrective action in material, design or process
- Verification that the fix holds
Material selection and metal-to-plastic conversion
Your resin is discontinued or too costly, or the part needs to be lighter.
Establishing equivalency for an alternate or backup resin takes real testing. We qualify substitutes for cost, supply-chain or performance reasons, and convert metal parts to plastic, such as multi-step machined stainless replaced by one-shot carbon-fiber PEEK.
You receive
- Qualified material with test data
- Process adjustments for the new resin
- Weight and cost comparison
Reverse engineering, onshoring and training
You have a sample and no drawings, a mold coming home from overseas, or a team that needs to grow.
We 3D-scan parts and rebuild them as fully parametric models, then go straight to mold and production. We bring offshore molds back, adapt them to US standards and repair them. We also train operators, technicians and engineers.
You receive
- Parametric CAD from a physical part
- Molds reworked and running in the US
- Training in molding, extrusion and materials
