We support our advanced materials innovation with world-class technical expertise, innovation and customer collaboration.
We work closely with our customers to understand application requirements and optimize part design to improve performance and manufacturability. Molds are designed to support high output, low scrap and maintenance requirements. Our in-house toolmakers design and build secondary tooling and maintain production molds, including the following:
The presses used for injection molding are horizontally operated with a unique material delivery system. The thermoset compound is fed and injected with a high speed reciprocating screw or a plunger system that reduces glass degradation for better part strength.
This molding process utilizes a pre-staged charge of material that is created by manually or automatically cutting, stacking, arranging and weighing the individual SMC or TMC pieces. This charge is either manually or automatically loaded into the open mold. Once the charge is placed, the mold is closed with a fast closing speed followed by a controlled final closure speed once the thermoset compound begins to flow. As the compound flows in the mold, it reaches a telescoping shear edge zone at the perimeter of the cavity that enables air to escape.
Perfect for medium volume runs or highly detailed parts, the resin transfer process offers key advantages over open molding because it creates smooth surfaces on both sides of a part and it allows ribs and bosses to be molded in. Resin Transfer Molding offers lower cost tooling than compression molding although the surface quality approaches that of compression parts. Resin transfer is also useful for prototyping compression molded parts, since mechanical properties are similar.
Open Molding parts are appropriate for large parts with low to medium volumes and one finished surface. The process is capable of molding in undercuts and hardware such as brackets. Resin and gel-coats can be color matched to eliminate the need for secondary finishing. Hand lay-up parts are also used for functional prototyping. Open Molding utilizes low cost polyester molds built by our in-house Tooling Department.
Pultrusion is a manufacturing process used to produce continuous lengths of composite materials with constant cross-sections. The process involves pulling raw materials (liquid resin mixtures) through a heated steel forming die using a continuous pulling device.
Where precision machining is required, we can meet the tightest tolerances – and we have the capacity to meet demanding volume and scheduling requirements, as well. Highly-complex parts and those with extraordinary tolerances can be produced in our three-axis and five-axis CNC machining centers.
Finishing is performed with a level of craftsmanship and attention-to-detail that complements our precision manufacturing processes. Quite often, an excellent finish and color can be molded into the product. When that’s not possible, we offer a variety of paint finishes, including smooth, blemish-free painted and silkscreened parts, high gloss painting, as well as texture painting, which offers a uniform appearance from lot to lot – and with six paint booths we have the capacity to meet demanding volume and scheduling needs.