Project Walk-Through (Project Overview)
Do you have a custom part or manufacturing project in mind?
Here is a walk-through of the typical steps in one of our complete "design to delivery" projects.
Two quick points before we begin:
- Already part way through a project? Don't worry: We can start our support for your project at any stage in the sequence below.
- Our goal is to serve as your full-service center for custom injection molding (and associated manufacturing operations), to solve the part-related challenges you are facing, and to help you stay competitive in today's market.
Step One
Consultation
Whether by phone or in person, in this step we first listen to your product requirements - or perhaps even more basically, consider together the particular problem you are encountering that may require a manufactured solution. Even if we conclude that Penn Plastics is not the best suited to help, we can often direct you to the manufacturing process that fits your application. If we feel we can help, we will prepare a quotation with material and process specifications, as well as estimated time to completion.
Step Two
Product Design
In this step our engineering staff develops a detailed drawing of the proposed part in 3-D CAD software. The specific design takes careful consideration of all the relevant factors: functionality, ease of assembly, mold-ability, and the high quality and reliability standards which your company demands. Our in-house CAD software is SolidWorks, but the resulting 3-D files and 2-D prints can be translated into a variety of formats depending on the needs of our customers. When the design is approved, we can proceed to the next step.
Step Three
Prototypes
Functional sample parts are an opportunity to refine the design in real application. (In some situations this step may be unnecessary and we can move directly from product design to production molds below.) Prototypes and rapid prototypes can be made by a number of processes, and which one we would recommend will depend in part on the product design, material, and type of test desired. One process produces samples through a method called SLA (short for Stereo lithographic Apparatus); another approach is to machine parts from plastic block or sheet; and a third approach is to mold parts in a single-cavity sample mold. Oftentimes a single-cavity sample mold can not only assist in finalizing part design but produce the initial quantity of saleable parts while the production mold is being built.
Step Four
Production Molds
In this step the production tool (or tools) are built to mold the parts as designed and refined. Penn Plastics produces high-quality molds to last for many years. Mold costs and part cost have been quoted in detail earlier in the process. One important concept is cavitation. Our recommended cavitation takes into consideration your potential demand. In some cases a single-cavity mold (that is, a mold that makes one-part at a time) is more than adequate. In other cases, cavitation for 4, 6, 8 or even 16 parts at a time may be recommended. In general a higher cavitation mold is more costly to produce, but the parts themselves produced on such a mold are less expensive each. So the right balance is needed, and we will quote the various ratios so you can chose what is best for your company.
Step Five
Production
Our purpose is to support your company in ongoing quality production. Our skilled technicians and machine operators will produce your parts to specification. These are the parts designed to solve that particular problem, or fill that particular marketing niche, that originally brought you to us in the first place! Since these parts are made right at our plant in Connecticut, production lead times can be quite short and, of course, there is no need for long in-transit shipping time frames.
Step Six
Assembly, Decorating, Packaging
In many instances, the part is complete as it leaves the mold. But for others we can finish the part with a range of in-house secondary operations, including assembly (mechanical, sonic welding, chemical bonding), decorating (labeling, hot stamp imprinting or screen printing) and specialized packaging.
Step Seven
Shipping and follow up
We will package and (when applicable) palletize your product in a way that maximizes in-transit safety and cost-effectiveness. In many instances we can keep parts in our warehouse and ship on demand to you or even distribute to your customers. We will not be satisfied until you have the product you requested, safely, and at a fair price. We are geared for long term service to you and your company.
Ready to discuss your project? We look forward to speaking with you. Call us at 1-800-490-7366
