With global supply chains suffering from uncertainty, more businesses are turning their attention back to domestic manufacturing. At the same time, there has been an increasing need for molded plastic parts that meet tight tolerances and strict quality control requirements. If you are considering production on new plastic components with a U.S.-based injection molding company, there are certain steps you should take. Below, we’ll walk you through the process and also outline the benefits of manufacturing in the United States. And don’t worry, whether you’re re-shoring a previously overseas production or getting a startup off the ground, the process is similar.
Designing the Component
The first step involves taking an idea or concept and translating it into a design that reflects a real-world object. Today, this takes place less on drafting tables and more on computer desktops. Software such as SolidWorks and other industry-leading CAD software makes it possible. A plastic injection molding manufacturer such as Reliant Plastics can assist you with the design phase and can even produce a prototype that leverages the benefits of additive manufacturing, such as a rapid turnaround time. We use this prototype to validate the design, assess any issues, and make final adjustments. Only once our team and yours are satisfied do we move on to the next phase.
Creating the Mold
You may already have a complete part design ready to go, or you may need to wait on your molding team’s engineers to finish the design. The next step involves the creation of the mold tooling itself. This is where the benefits of a digital transformation in manufacturing become clearest, as the team uses computer software to fabricate the design before manufacture.
Tools such as Moldflow simulate the physical act of injecting thermoplastic resin into the mold design. In this simple step, engineers can see where challenges may develop and issue design tweaks before you make a major investment in production-level tooling. If additional components go into the mold, such as materials for overmolding, we will consider them during this key design stage. Our goal is to design molds that capture the benefits of lean manufacturing, reducing waste and improving value.
Mold Tooling and Manufacturing
With the completed mold design, it is time to produce the actual tooling for use in a plastic injection molding machine. The number of tools necessary will depend on the volume you require from each production run. By working with Texas injection molding manufacturers, you can take advantage of shorter manufacturing lead times while exercising greater control over the quality and safety of the production. Tooling can traditionally have long lead times involved. However, coordinating with a team such as ours provides total visibility and transparency throughout the process. During the tooling process, accuracy to the design undergoes frequent checking and re-checking.
Once the tooling is complete, manufacturing runs can begin. After much hard work, it’s time to start bringing your products to life. From the first run to the last, quality is always a primary concern. This is where our focus on quality control versus quality assurance becomes important. During design and tool creation, quality assurance procedures ensure that we produce the best possible outcomes. Control is how we make sure we’re hitting that high mark.
Quality Control
What is quality control, and why is it an essential element to the success of your project? Quality control jobs involve a quality control inspector examining and measuring parts to confirm that they align with the original design. This step is essential for identifying deformities or anomalies that might appear in the injection molding process. Over time, the metal of an injection molding tool can warp and degrade. These processes identify problems and ensure they do not reach the end user.
Good quality control is the definition of a reliable manufacturer, because it ensures that the finished products have the appropriate material qualities as designed. Through the employment of tolerance gauges, sigma-level sampling, and more, a plastics company near you, such as Reliant, can deliver exceptional results that represent excellent value for your investment.
Kitting and Other Value-Added Services
Alongside insert molding and overmolding procedures, which produce finished or nearly complete components at the end of a molding run, a U.S.-based manufacturer can also offer other essential services. Kitting is one such opportunity for added value. Instead of shipping bulk components to your business for additional processing and packaging, kitting involves manufacturer assembly of the completed parts after molding. You then receive a finished product ready for sale or further finishing without the need to invest in additional in-house services, giving you all the benefits of contract manufacturing.
Storing and Maintaining Molds
Molds require careful maintenance between production runs to maintain their effectiveness and continue producing parts within the correct tolerances. Without maintenance, the wear and tear of thousands of cycles in an injection molding machine can lead to parts that no longer conform to their specifications. Your manufacturer should have the appropriate facilities for not only storing molds in between runs, but for cleaning and maintaining them as well. Inspections that reveal tool wear, no matter how slight, can lead to critical repair work that keeps molds producing excellent results throughout their lifecycle.
Working with Reliant Plastics to Fabricate Parts
At Reliant Plastics, we are consummate professionals and fully equipped to work with businesses throughout the United States who require end-to-end injection molding support. From initial design to kitting and more, our experience opens the door to on-shore production that is cost-effective and quality-assured. We fully leverage the benefits of automation in manufacturing to provide our clients with the best outcomes on the shortest possible time scales.
Next time you’re wondering, “Where is a provider of injection molding near me in the U.S.?” just remember Reliant—and that we’re right here. Learn more about the benefits of outsourcing manufacturing and working with us today when you contact our team.
