Mold Design, Build and Engineering Services(Click on thumbnail to enlarge)  Mold Design, Build and Engineering Services |  Mold Design, Build and Engineering Services |
The basis for providing a quality product is the design. Our Design Department employs full time Design Engineers using the most advanced modeling software. Our Unigraphics CAD/CAM software enables us to machine the details of the tool directly from the design data. This not only cuts the lead time for supplying production parts, but the potential for human error is also greatly decreased. Acceptable file formats include SolidWorks, UGII, Parasolids, and Iges files. Design Profile- Engineering assistance with product design.
- Is it moldable? Manufacturing assistance.
- SLA - rapid prototyping services available.
| - Mold flow & mold cooling analysis available.
- Multiple disciplined designers (Journeyman toolmakers).
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Within our Engineering Department, our professional staff of Design Engineers provide you with the innovative ideas you need to ensure your product's success. With our Unigraphics UGS CAD/CAM software, the integrity of your part data is maintained throughout the entire process. After creating a solid model of the mold, the cavity detail is machined with the latest technology CNC milling and EDM equipment. The molded part is then measured and compared to your original part file with our Browne and Sharp CMM. (Click on thumbnail to enlarge)  CNC RAM EDM |  Mold Stak System |  Design Center | | |  Makino CNC Wire EDM |  Master Tool Builders #1 |  Master Tool Builders #2 | | |  Master Tool Builders #3 |  EDM Burning |  Precision Grinding |
DownloadsCapabilities| Capabilities |
| Instrumentation Components
CNC Milling Centers High Speed Hard Milling
Wire EDM with Turn and Burn Capabilities
Sinker EDM
Heliarc Welding
Heat Treat
Pad Printing
Hot Stamping
Ultrasonic Welding
Hand Polishing
Blast / Deburr
Insert Injection Molding
Injection Molding
Assembly | Inspection
Clean Room
Customer Barcoding and package labeling
Prototyping
Metal/Polymer Machining
Unigraphics Design Software (NX3, NX4, NX5 and NX6)
CNC Machining Ram EDM
Precision Grinding
Custom Assembly
Secondary Operations
Engineering Consulting Services
PC-DMIS software
Brown & Sharp CMM measurement system
720 position Renishaw Probe |
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| | Facility |
| Tool Room 9,240 sq. ft. Manufacturing 32,780 sq. ft.
Total 45,460 sq. ft. Offices 3,440 sq. ft. |
| | Company |
| Certified to the ISO 9001 Standard October 1996
Certified to the ISO/IATF 16949 Standard in
March of 2018 |
| | Engineering File Formats |
| Assembly FEM Files (*.afm)
Bookmark Files and PLM XML (*.plmxml)
Bookmarks - Pre NX4 (*.bkm)
DWG Files (*.dwg)
DXF Files (*.dxf)
FEM Files (*.fem)
I-DEAS Exchange Package (*.xpk)
IGES Files (*.igs)
JT Files (*.jt)
Parasolid Binary Files (*.xmt_bin)
Parasolid Binary Files (*x_b)
Parasolid Text Files (*.x_t)
| Parasolid Text Files (*.xmt_txt)
Part Files (*.prt)
Simulation Files (*.sim)
Solid Edge Assembly Files (*.asm)
Solid Edge Part Files (*.par)
Solid Edge Sheet Metal Files (*.psm)
Solid Edge Weldment Files (*.pwd)
SolidWorks Assembly Files (*sldasm)
SolidWorks Part Files (*.sldprt)
STEP Files (*.stp)
User Defined Feature Files (*.udf) |
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| | Tool Room |
| High speed CNC milling machines.
In-house heat treating and polishing.
Wire, sinker and EDNC EDM machines. |
| | Injection Molding |
| 1 vertical injection molding machine.
18 horizontal injection molding machines (10 all-electric servo driven).
Star,
Sepro and Yushin robotics. |
| | Decorating / Finishing |
| Hot stamping.
Labeling. | Pad printing.
Ultrasonic Welding. |
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| | Quality Control |
| QAS Version 3.1 SPC Software.
Servo-driven CMM.
Video and optical comparators. | | |
back to top Tool Room Equipment List| Makino SP43 CNC Wire EDM |
| 1,764# Table Load
17.8" x 11.8" Table Travel, 12.6" Z Axis
33.5 x 28.3 x 12.6 Max Work Piece | Accuracy ±0.000060"
Repeatability ±0.000060" |
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| | Makino SP64 CNC Wire EDM |
| 2,645# Table Load
25.5" x 15.7" Table Travel, 16.5" Z Axis
33.5 x 28.3 x 12.6 Max Work Piece | Accuracy ±0.000060"
Repeatability ±0.000060"
Turn and Burn Capable |
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| | Makino S56 Vertical Machining Center |
| 1325# Table Load
35.4" x 19.7" Table Travel, 17.7" Z Axis
20 Station Tool Changer | Accuracy ±.00006"
Repeatability ±.00004"
Equipped with Blum Laser System |
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| Kitamura CNC Mycenter-3X
Vertical Machining Center |
| 1100# Table Load
17.9 x 29.9 Table Travel, 18" Z Axis | 20 Station Automatic Tool Changer
Tolerances within a 1' cube, ±.0002" repeatability |
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| | AGIE Mondo Star 50 EDM |
| 16 Station 3R Tool Changer
300 Amp Power Supply
3D Orbit Capabilities | Integrated C Axis
Travel X-20" Y-14" Z-14"
Work Weight - 1100# Electrode Weight 220# |
|
| | Hansvedt (Leadman) RAM EDM |
| 10½" x 13½" x 16" Table Travel
1650# Work Weight
3R Orbicut CNC Attachment and an Anilam Digital Readout
60 Amp H-Pulse Power Supply with System
First Spark 3 Axis Digital Readout
Repeatability ±.0002" |
| (4) Vertical Mills with
Attachments |
| 12" x 24" |
| | Bridgeport Vertical Mill |
| 15" x 33"
1500# Workload Capacity |
| | (6) Chevalier Surface Grinders |
| 6" x 18" |
| | Chevalier Wet Grinder |
| 16" x 40" |
| (6) Boyar-Schultz Surface
Grinders |
| 6" x 12"
6" x 18" |
| | (2) Harig Surface Grinders |
| 6" x 18" |
| | Clausing Lathe |
| 13" x 42" |
| | Arboga Radial Arm Drill Press |
| 3½' |
| | Rockwell Drill Press |
| 20" |
| | Drill Press |
| 24" | | |
back to top Production Equipment List| Molding Machines |
| (1) 40 Ton JSW Electric 0.8 oz.
(1) 55 Ton JSW 2.0 oz.
(1) 85 Ton JSW 3.1 oz.
(1) 110 Ton JSW Electric 4.3 oz.
(1) 110 Ton JSW 5.6 oz.
(1) 120 Ton JSW Electric
4.3 oz.
(2) 120 Ton JSW Electric 5.6 oz.
(1) 154 Ton JSW Electric 4.3 oz. | (2)
200 Ton JSW Electric 7.3 oz.
(1) 200 Ton JSW Electric 9.6 oz.
(3) 245 Ton JSW 17.8 oz.
(1)
242 Ton JSW Electric 11.2 oz.
(1) 310 Ton JSW 28.6 oz.
(1) 385 Ton JSW 28.6 oz.
(1) 115 Ton Nissei Hybrid 6.1 oz Vertical Rotary |
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| | Auxiliary Molding Equipment |
| Central Material Conveying System
(3) 15 CFM Dehumidifying Hopper Dryers
(2) 20 CFM Dehumidifying Hopper Dryers
(8) 25 CFM Dehumidifying Hopper Dryers
(3) 60 CFM Dehumidifying Hopper Dryers
100 CFM Dehumidifying Hopper Dryer
(2) Mold Temperature Controllers (Oil)
(24) Mold Temperature Controllers (Water) | (3) Conair 4-Component Pellet Additive
(3) Parts Conveyors & Parts Separator
(5) Sprue Picker Robots
10 Ton Chiller
Gravimetric Blenders
Numerous Hot Runner Control Units
50 Ton & 30 Ton Cooling Tower
Tower Treatment System |
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| | Robots |
| (1) Star T600VI-480
(1) Yushin ATX-II 300 SL
(2) Star TW 1000V 460V2 | (2) Star TW 800V-460
(6) Sepro 5X-15 5 Axis |
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| | Finishing Equipment |
| (2) 3" Pad Printer (Dual Sealed Cup)
(2) 900 Watt Ultrasonic Welder / Inserter | (2) Label Applicator Machine
1 Ton Hot Stamp Machine (1 to 4 Color) |
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| | Clean Room |
| 20' x 30' Soft Wall Portable Clean Room |
| | Material Handling Equipment |
| (2) 5000 lb Forklift
6000 lb Forklift
Pallet Jacks
Parts Counting Scales | Plastic Granulators
Platform Scales
Rotary Screw Air Compressor with Dryer |
| | |
Quality Control Equipment List| Brown and Sharpe CMM |
| Model 07.07.05 (CNC) (Adjusts to temperature variations)
PC Dmis Software,V-4.3
Datapage/RT Software V-3.33
Renishaw PH10 Probe Head (720 Positions)
28X x 26Y x 18Z |
| Deltronics DVC-120 Video
Comparator |
| 6" x 12"
14" Color Video Monitor
Display Monitor |
| | Quality Control Equipment List |
| Deltronics MPC-5 Optical Comparator
Unitron ZSB Microscope
NWA QAS Version 5.1 SPC Software | Vision Inspection System
Mitutoyo SJ-201 Surface Profilometer |
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back to top Quality Profile- Extremely low ppm levels for all parts.
- Complete first piece layout capable.
- 3 shift in-process inspection.
| - Conform to AIAG standards.
- Quality Control Plans, FMEAs
| | |
Quality AssuranceOur Quality Assurance Lab is equipped to handle inspection of the most difficult of parts. Utilizing a servodriven Coordinate Measuring Machine along with optical and video devices, part layouts and in-process inspection are a snap. As an ISO 9001
and ISO/IATF 16949 certified molder, our quality manual and procedures are well defined and documented. Services Offered- Scientific Injection Molding, Process Optimization and the Universal Set-Up Sheet.
- 3D solid design, Unigraphics NX6 and SolidWorks 2009.
- Prototype mold build and run. Deliveries as quick as "ONE WEEK".
- Production mold build and run. We have all the latest and greatest technology including "HIGH SPEED HARD MILLING". Tools can be produced faster with greater accuracy.
- Metrology Lab with "Servo Driven, 720 positions Renishaw Probe, B&S CMM", and video comparator.
- Horizontal and vertical molding machines, 40 to 385 ton. Allowing a wide range of product sizes as well as insert molding.
- Robots and conveyors for those special needs.
- Pad printing.
- Heat stamping.
- Sonic welding.
- Labeling.
- Assembly.
- Portable clean room 100,000 clean room.
- ISO 9001 and ISO/IATF 16949 certified.
Scientific Injection MoldingA good part is the culmination of proper resin selection, component design, tool design, tool construction and processing. Each is equally important and must be done correctly. - Faster product development.
- Fewer engineering changes.
- Faster time to market
- Higher quality.
- Higher return on assets.
- Higher white collar productivity.
- Easier life on production floor.
- Plastics point of view to forming identical parts consistently.
- Scientific approach to establishing all molding variables.
- A process where the machine adapts to changes in viscosity not the operator.
- The ability to move from press to press and reproduce part consistency.
- Viscosity versus flow rate, pressure loss, gate seal and short shot studies.
Customer Benefits- In business for
51 years. Management Team with over 200 year of experience.
- ISO 9001 and ISO/IATF 16949 certified.
- Scientific Injection Molding - We build ready to run molds.
- Seamless take over of all custom injection molding services.
- Structured project management reduces lead-time for quick to market requirements.
- We partner with local and off-shore businesses to meet all your goals.
- Lean manufacturing principles applied to all processes.
- Climate controlled facility for enhanced process control.
- Design, tool build, production, qualification and secondary operations all under one roof.
- Wide range of press tonnage to service all your needs (40 to 385 ton).
- Horizontal and vertical molding machines.
- Financially sound with room to grow.
- A corporation founded on the principles of truth, honor and integrity.
- TPS principles applied
- Responsive Customer Service
- File transfer made easy. We can accept STEP, XT, IGES.
- Climate Control facility for enhanced process control.
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