Molding
USA Industrials is your solutions provider for molded parts
Overview
USA Industrials’ advanced molding capabilities allow us to custom design and mold products across a wide spectrum of plastic, rubber, and sponge/foam materials.
Base Molding Capabilities
Plastic Injection Molding: Plastic resin is heated into a malleable molten state and injected into a mold. The molded plastic then cools and solidifies before it is ejected.
Rubber Injection Molding: Rubber compound is heated into a malleable molten state and injected into a mold. The molded rubber then cools and solidifies before it is ejected.
Sponge/Foam Injection Molding: Plastic resin or rubber compound is heated into a malleable molten state, combined with a blowing agent, and injected into a mold. The blowing agent introduces air pockets into the component so that as it cools and solidifies, it becomes softer and more compressible.
Rubber Compression Molding: Rubber compound is preformed and placed into a mold cavity, which is then closed and heated. Good solution for prototyping since tools are simple, low cost, and can typically be made in house.
LSR and HCR Silicone Molding: Mixes a two-component silicone compound together, which is then heat-cured in the mold with a platinum catalyst to produce a final part.
Specialty Molding Capabilities
Overmolding/Insert Molding/Two-Shot Molding: Involves molding plastic or rubber around or into any substrate, including other plastic and rubber, metal, composite, ceramic, and glass, to create a single component.
Micro Molding: Involves molding plastic or rubber to create extremely small parts with complex geometrics, high precision, and micron tolerances.
Elastomeric Coatings: Involves application of a thin layer of higher-performance elastomeric coating, such as FKM and HNBR, to rubber parts to optimize the performance of the base material. Examples of performance enhancement include:
- Offering strength and isolation characteristics.
- Additional chemical and environmental resistance.
- Increased temperature capability.
- Change color to achieve performance, such as deflection of radiant heat.
Tooling
New Tooling
Custom plastic and rubber injection molding means that each and every job is different, and no two molds are exactly the same. Our expert engineers custom-design each mold to fit your production requirements.
Prototype: Limited quantity prototype parts; market testing; <500 parts.
Low Run Production Mold: For use with non-abrasive materials; limited runs; aluminum or MUD tooling; typically <10,000 parts annually.
High Run Production Mold: Hardened tool steel; most common price-range; tool design built to our internal standard; automated lifters or slides, good with abrasive materials; cold runners with the exception of a few hot runners; typically 100,000 to 1 million parts annually.
Extremely High Run Mold: Hardened tool steel; tool design built to our internal standard; multi-cavity, fully automated; generally hot runners; typically 1 million or more parts annually.
Transfer Tooling
Transfer tooling is an area of expertise where USA Industrials can help. If you are experiencing quality or capacity issues with your current molder, you can transfer your existing tool for a seamless shift in production.
Through our proven process and automated inspection, we will send you sample parts within a week of your tool’s arrival at our facility!
We ensure transfer tooling is a hassle-free process by extending our team of resources to your team, improving on the care and
quality of your tool. From our process engineers to our tool and diemakers, we dedicate our talents to your investment.