Custom Plastic Injection Molding Services & Manufacturing

From Concept to Completion

The Rodon Group is an industry-leading custom plastic injection molding provider, creating billions of high-quality parts annually. We are proud to be a United States manufacturer, and with over 120 injection molding presses, we are one of the largest family-owned molders in the U.S.

Rodon offers a wealth of custom molding knowledge and experience, taking a comprehensive approach to part design while featuring the following capabilities.

Turnkey Plastic Injection Molding Capabilities

Injection Mold Design & Engineering

Our design team has over three decades of industry experience building and designing top-quality molds. Advanced design software, such as Solid Works, allows us to quickly and easily modify and assess part designs to meet our customers' exact specifications.

Precision Toolmaking & Mold Building

Manufacturing a high-quality tool requires precision, accuracy, and time. Since it can be a significant investment in the manufacturing process, Rodon is committed to getting it right to ensure the success of your project. We offer the following advantages with our precision tooling capabilities:

• Warranty As long as we’re operating a tool that we have manufactured, there will never be any maintenance or repair charges.
• Tool Quality We build top-quality precision molds designed to achieve tight tolerances and optimized cycle times for your project.
• Capacity Our experienced and knowledgeable team has the capacity to mold parts with wall thickness variations and complex geometries.
• Maximum Part Size While we concentrate on parts with small dimensions, a 10" square is our maximum part size.

High-Volume Production & Cleanroom Molding

Our state-of-the-art facility includes 120 fully automated presses. Our production schedule runs seven days a week, 24 hours a day, for most of the year to ensure optimal efficiency.

• Facility and Equipment - Each of our presses has self-diagnostic and microprocessor-controlled functions, with clamping forces ranging from 46 to 720 tons and a fractional to 107-ounce capacity. We also have a new Class 8 cleanroom environment that can be adapted to meet the demands of various projects. This is especially beneficial to the pharmaceutical, medical, food and beverage, and other industries that must meet strict safety standards.
• Automation and Inventory Management - Rodon maintains a safety stock to meet our clients' unexpected demands. Our inventory levels are monitored in real time to help with future needs estimation. We also use a Material Requirement Planning (MRP) System for efficient job monitoring from beginning to end. Our extensive expertise in resin properties, part demand, and cycle times contributes to our 99.8% customer satisfaction rating.

Quality Control

Our quality control checks play a vital role in our manufacturing process, and we conduct them at every phase of production. These checks include an assessment of color accuracy, tolerances, strength, part defects, and the overall physical appearance of a product. Our comprehensive approach to quality control is essential to maintaining high standards in our manufacturing processes.

Industries Using Custom Injection Molded Parts

At Rodon, we work with the following industries to create custom-injected molded plastic parts:

• Medical / Pharmaceutical: Rodon can mold a variety of medical and pharmaceutical parts for applications such as laboratory tools, testing instruments, medical equipment, and other devices. To ensure optimal safety, we also offer cleanroom solutions to provide a sterile production environment.
• Window & Door:We produce top-quality, high-performance parts for window and door manufacturers. Applications include latches, vent stop keepers and locks, muntin clips and joiners, and more for commercial and residential purposes.
• Food & Beverage: Plastic injection molding is ideal for creating complex, identical parts with food-grade plastic materials. Rodon can manufacture food and beverage components in adherence to FDA and related regulatory standards. Additionally, we offer cleanroom solutions to ensure a safe, contaminant-free manufacturing environment.
• Building & Construction: Plastic injection molding plays a vital role in the building and construction industry, with applications that include flooring, walls, roofing, windows, piping, insulation, and more.

Plastic Molding Material Selection & Resins

Material Selection

There are various materials to choose from when it comes to plastic injection molding. To ensure your parts perform as needed, the experienced team at Rodon can guide you in selecting the proper material for your unique plastic injection molding project.

Not sure which resin to use? Consult with our engineers.

Advantages of Custom Plastic Injection Molding

As one of the most versatile methods for plastic part production, plastic injection molding has numerous advantages over other methods. Custom plastic injection molding is not only a more straightforward and more reliable process than others. It also offers the following benefits:

• High efficiency with fast production
• Complex part design with a high level of consistency
• Enhanced strength
• Flexibility of material and color options
• Reduced waste
• Lower labor costs over other types of molding

Partner With The Rodon Group For Your Next Injection Molding Project

At The Rodon Group, we are a leading U.S. provider of custom plastic injection molding services. We are ISO 9001:2015 and ISO 13485-certified to ensure the highest level of quality for every project, and our comprehensive capabilities allow us to meet the needs of many industries. Regardless of your needs, the experts at Rodon can deliver superior components that adhere to tight tolerances.

Contact us to learn more about the cutting-edge services we offer. You can also request a quote to work with us on your next project.

Frequently Asked Questions About Custom Plastic Injection Molding

Q: What is your maximum part size and press capacity?

A: We specialize in high-volume, small-to-medium-sized parts. Our maximum part size is a 10-inch square. Mostly our parts are 3″x3″x3″ and smaller. To support this, our facility operates 120 fully automated presses with clamping forces ranging from 46 to 720 tons, and shot capacities ranging from fractional up to 107 ounces.

Q: Can you accommodate complex geometries and varying wall thicknesses in your mold designs?

A: Yes. Our toolmaking team utilizes advanced design software (such as SolidWorks) to analyze and optimize part designs prior to cutting steel. Our precision molds are engineered to manage complex geometries, achieve tight tolerances, mitigate warping in parts with wall thickness variations, and optimize cycle times for high-volume production.

Q: Do you offer cleanroom injection molding for medical or food-grade applications?

A: Yes. We operate a new, adaptable Class 8 Cleanroom environment within our facility. This allows us to manufacture components in a sterile, contaminant-free setting that adheres to strict FDA, medical, pharmaceutical, and food and beverage regulatory standards.

Q: Who owns the mold, and what are the maintenance costs over its lifespan?

A: The customer owns the mold. However, as part of our turnkey manufacturing approach, Rodon offers a unique, lifetime tool warranty. As long as we are operating a tool that we have manufactured in-house, you will never incur any maintenance or repair charges for the life of that project.

Q: How do you handle inventory management and mitigate supply chain disruptions?

A: As a 100% U.S.-based manufacturer (Hatfield, PA), we inherently reduce the risks associated with offshore shipping delays. To further protect your supply chain, our automated facility runs 24/7. We utilize a Material Requirement Planning (MRP) System and monitor inventory levels in real-time, allowing us to maintain safety stock and rapidly respond to unexpected spikes in your demand.

Q: What quality control standards and certifications do you hold?

A: We maintain a 99.8% customer satisfaction rating through rigorous, multi-phase quality control checks (assessing tolerances, strength, color accuracy, and defects). Our manufacturing processes are formally backed by ISO 9001:2015 and ISO 13485 certifications, ensuring consistent, high-quality production across all industries.

Q: Is plastic injection molding the most cost-effective method for our production volume?

A: For high-volume production, custom plastic injection molding is highly cost-effective. While the initial investment in precision toolmaking is significant, the per-part cost drops dramatically at scale. The process offers high efficiency, rapid production cycles, high consistency, reduced material waste, and lower labor costs compared to other molding methods.

Q: How does partnering with a U.S. manufacturer like Rodon impact our overall ROI?

A: Reshoring or partnering with a domestic manufacturer like Rodon improves ROI by eliminating international freight costs, reducing lead times, and bypassing tariffs and complex customs logistics. Furthermore, our highly automated facility - running 125 presses 24/7 - allows us to offer highly competitive, high-volume piece-part pricing while maintaining strict U.S. quality standards and IP protection.

Q: Do you offer post-molding assembly services for multi-part plastic components?

A: Yes. To provide a complete, turnkey manufacturing solution and streamline your supply chain, Rodon offers both semi-automated and fully automated high-speed assembly services. The ideal assembly approach depends on the specific nature of your part, annual volume requirements, and component complexity:

• Fully Automated High-Speed Assembly: Ideal for ultra-high-volume, highly repeatable projects where maximum throughput, cycle-time minimization, and strict consistency are required.
• Semi-Automated Assembly: Best suited for projects requiring a blend of robotic precision and operator inspection, or for complex geometries that benefit from flexible, human-assisted placement.

Integrating custom assembly directly at our facility eliminates the need for third-party secondary processors, lowering your total cost per part and reducing shipping delays.

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Videos

Read Video Transcript

So the Rodon Group has been in business since 1956. We've been a plastics injection molder, we're a third-generation family business, and we make billions and billions of parts every year for a variety of industries.

We've been in medical molding in a limited way since about 2008, and it's really ramped up since the pandemic. We've opened up a division to focus specifically on medical manufacturing. We recently built a state-of-the-art cleanroom. It can be a Class 8 cleanroom. It can also be run as white space.

Certainly with healthcare, some of the great fits for our new cleanroom would be anything pharmaceutical, medical — food and beverage would be a big one — and any other industries that need a secondary operation where they need the components cleaned, such as maybe they're putting a reflective coating on a lens. We're excited — we can make billions of parts in there now. We've already got our first three projects in there.

The precision required in almost every medical application is above almost any other industry. So you're talking about diameters of a human hair you're trying to measure, and injection molding allows you to do that. It also allows you to have a variety of materials to choose from. So they maybe need something that's a little bit softer and moves, or something that's very rigid, or something that has glass in it or doesn't have glass in it. So all of those things — and of course, sanitization. And injection-molded plastic, when we pick the right kind of medical-grade plastics, allows that to be sanitized very easily as well, and stay cleaner. So those are all of the advantages that injection molding provides for the medical field.

Here at Rodon, we do everything internally: from tooling design, tooling construction, molding, secondary operations, bagging, sonic welding — and we also do assembly. That is what is a big advantage of using Rodon over multiple sources: you come to one roof, it all happens here, and because of that, we lifetime-guarantee the parts.

So we think that the world has changed from "just in time" to "just in case." And so what we mean by that is that there's all kinds of supply chain disruptions, supply chain spikes, and sometimes demand spikes and demand drops. So how do you deal with that? We've decided to invest in inventory. We just don't let people down. If we've got to bring somebody in at three o'clock in the morning in order to get something out the door the next day — because for whatever reason your inventory wasn't correct, or you need more parts than you originally thought you needed — we'll do everything we can to help you out.

So if you need it inspected every cycle, we can do it. If you need it inspected once a shift, we can do it. If you need it hand-inspected, we can do it. And we've doubled the size of our QC lab over the last year and a half now, because we have more business that requires it and because we want to be ready for the future as we see the regulatory requirements increasing.

The quality's there, the output's there, and the customer gets what they're looking for. Continual improvement is part of our core philosophy. Our goal always is to be the strongest link in your supply chain.

Clean Room Injection Molding | The Rodon Group/Sterling Healthcare

Read Video Transcript

We are a third-generation family business entirely focused on advanced manufacturing. We specialize in plastic injection molding, and we make sure that every day we are the strongest link in your supply chain. To facilitate our injection molding operations and further enhance our customers' experience, we commit ourselves to continually integrating the newest molding technologies and industry techniques. State-of-the-art is our model — from implementing sustainability initiatives to automating our molding facility. These changes to our company allow us to offer our customers more personalized and innovative turnkey solutions. The mantra is the turnkey solution: we design, we build, we run. This level of control and quality enables us to stand behind anything we build for the customer. As long as we're running the mold, there is a complete warranty for all repairs and all maintenance — there's never any other kind of upcharge.

Up until 1989, we were primarily an injection molder of caps and plugs and a custom molder. In 1989 I designed K'NEX, and that frankly changed the world for us. We went from about 70,000 square feet and perhaps 70 presses to where we are now — we occupy approximately 250,000 square feet and have 119 presses in sizes from 40 tons up to 750 tons. We then went on to our newest venture, which is something called SillDry. It is a sill pan: when a building settles, the tendency is for the windows to crack in the corners, so we've designed sill pans that expand like an accordion, with end sections and center sections that can build to whatever size is needed.

Sustainability is important to Rodon because one of our core values is that we want to leave things a little better than we found them. It comes through in the integrity of the products we make, and it comes through in the way we go about the manufacturing process itself. We know that resources are important to all of us — we only get to live on one planet — and we want to make sure that we protect our little part of the world.

At Rodon, we take our core competency — high-volume precision parts at the best possible price — into any industry that has that requirement. Today we're in med-pharma, construction, medical, and window and door hardware, just to name a few — very diverse. All of those things require a lot of technical expertise that you don't see. All you see are great, precision-made parts showing up where you want them, every time you need them.

With over six decades of experience in the plastic injection molding industry and a state-of-the-art automated molding facility, The Rodon Group has the skills, knowledge, and tools to offer cost-effective and high-quality injection molding solutions in everything we do. It is our family motto to strive for quality, efficiency, and sustainability. As you think about building your supply chain, you want an expert at every link, and here at The Rodon Group we're focused on innovation and efficiency, and thinking about the future and your needs. We encourage you to check out our website and reach out to us for a quote.

About Our Company

Read Video Transcript

At Rodon, we're always thinking about the best way to make our customers' lives easier, and we think that makes sense by doing everything from design to manufacturing on the production floor. The Rodon Group is world-renowned for the production of injection molded components of the highest quality and precision — starting with our advanced design software, building your stainless steel tool using our automated EDM and CNC milling machines and optical measuring systems which can verify accuracy within 1/10,000th of an inch, to manufacturing your parts in our state-of-the-art robotics facility with over 110 injection molding machines. We serve a diverse group of industries including windows and doors, medical and pharmaceutical, consumer products, construction, food and beverage, and toys. From concept to completion, your project is overseen by our expert staff of professionals and a workforce of American craftsmen, all under one roof.

Rodon was a very, very small company, and to both my dad's and my mutual surprise, I was actually quite good at running the company. We had a great group of employees — and still do; most of them have been here a long time, some as long as 40-plus years. We don't have any turnover; the only people who basically leave are people who retire.

We've been manufacturing in the United States since 1956, and while some people have gone offshore and some are coming back, we've been here that whole time. We focus on strengthening your supply chain. Your supply chain is made up of all these links, and one of the biggest links — and the weakest link — is when you have to bring things in from five, six, seven, eight thousand miles away. What we do here at Rodon is give you the strongest link by having a domestic supply chain, where you have the entire turnkey operation of high-volume plastic injection molding here. So not only are our parts less expensive than the parts you import from overseas and from China, but you get the benefits of speed to market and the benefits of the American ingenuity and American quality that we have built over the last 56 years. When you are competing on a global scale, it's all about doing all of that — automation, technology, and innovation — together in a way that helps our customers. That's what we're 100% focused on right here at Rodon, every day.

The Rodon Group Capabilities

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Educational E-Books

Want to learn more about plastic injection molding? Download and enjoy our two carefully written comprehensive volumes!

An Intro to Plastic Injection Molding

How to Manufacture A Perfect Injection Molded Plastic Part