Companies in industries like medical, automotive, retail, construction, and many others rely on plastic injection molding services to reliably create the intricate parts they need for a wide range of applications. However, for certain projects, standard parts aren't enough When you work with a custom molder, each project is carefully evaluated to determine the level of customization you need.
When to Use a Custom Injection Molder
There are many situations in which you might turn to a custom injection molder to ensure your components meet your specifications:
- When you require high levels of precision and tight tolerances
- When you need to meet specific safety standards or industry regulations
- When you want to improve the mold quality
- When you need to find ways to reduce your costs
- When you're working with complex dimensions and geometry
- When you work in a niche industry or find yourself in a situation that requires a manufacturer with varied experience
Case Study Examples
Over the years, we've had the opportunity to work with many companies on specific projects. These case studies highlight the benefits of working with a custom plastic injection molder:
Plastic Injection Molded Residential Window Hardware
When this major door and window company contracted The Rodon Group, they were using hardware that was manufactured in-house for their residential windows. Unfortunately, their tools weren't good enough to produce exceptional results, and the quality of their products was diminished because of it.
We redesigned the tooling to create a high-quality design at a lower price point, and, with our advanced 46 to 233 ton Nissei presses, held a tight tolerance of ± 0.005" on parts ranging from 3/8" diameter to 4" square in size, and 0.03 grams to 20 grams in weight. In addition, accuracy and quality were verified via first piece and in-production inspections. Plastic Injection Molded Point-of-Purchase Display Components
For this company in the POP display industry, our value-added services helped them save money over the life of their products, which included pegboard hooks, shelf dividers, and product stops. We designed and built molds around a variety of pre-designed parts, and the upfront costs of high-production injection molding with tight tolerances were mitigated over time because these items were made from high-quality materials and built for long-lasting performance. We built the molds with electrical discharge machining, an advanced process that allowed us to keep tolerances of ±.005" with a highly polished finish.
Plastic Injection Molded Polystyrene Diagnostic Kit for the Medical Industry
Using 177-ton Nissei hydraulic presses equipped with a visual inspection system, we created a lateral flow in-vitro diagnostic test cartridge for a medical equipment manufacturer. These medium-impact polystyrene cartridges weighed eight grams with dimensions of 5/16" x 7/8" x 3 ¾" and a matte finish. With careful design and fabrication, we were able to offer a higher-quality component at a lower cost and part weight.
Plastic Injection Molded Custom Beverage Cap for the Food/Beverage Industry
This client had originally gone offshore for cap manufacturing to take advantage of low costs, but it resulted in a sub-par product that wasn't meeting the client's expectations. They needed a cost-effective solution and fast. The required hot roller process is not inexpensive, but we were able to leverage our experience and available equipment to offset that investment and create a high-quality cap.
On-Demand or Just-in-Time Manufacturing
Creating products to meet your demand, rather than manufacturing a surplus, has a number of benefits. Just-in-time manufacturing offers efficiency and shorter production times. It also ensures your manufacturing partner has a vested interest in your success to ensure you come back and place another order, which results in dynamic, high-quality designs, strong manufacturing, and quality assurance. Working with a full-service company helps you save money because you can complete all stages of the project under one roof with one set of quality and safety standards.
You also save money by avoiding the need to store inventory which, in some cases, could become obsolete by the time you need it. Proper inventory and production planning ensure you still have the products when you need them.
Key Factors for Successful Operation/Mold Making
The success of your product starts with the mold itself. Investing in a high-quality mold helps ensure consistent product quality and durable components. The best plastic injection molds have a few things in common:
- Innovative and precise design and engineering
- Stainless steel mold bases and cavities
- Modern, well-maintained manufacturing equipment
- A system that ensures precision and accuracy
It's all about the details. When you tend to the details, a well-built mold can last for decades.
For custom plastic shapes of all sizes and complexities, The Rodon Group has decades of experience and an ISO 9001:2015 certified facility featuring top-of-the-line equipment. Our custom solutions serve clients in a range of industries, and we'd be happy to work with you, too. Contact us to learn more about custom plastic fabrication or request a quote.