Heat Staking Solutions
Heat staking is one of the many processes used in plastic assembly when at least one of the parts is made from thermoplastic. In most cases, heat staking is the preferred method for joining metal parts to plastics. It is also used to join two dissimilar plastic components.
Heat staking process combines the use of heat and pressure, to soften a specific area of the plastic enough to be remolded into a new shape or profile that forms over or around the connecting part. Once cooled, it is the plastic’s strength that holds the mating part in place.
With heat staking, you have a permanent assembly without the use of other fasteners or hardware. Heat staking can also be used to add metal inserts to aid in multi-part assemblies. Heat staking has been found to be a very effective, controllable and repeatable process.
Because heat staking is performed after a part is molded, part assembly considerations need to be taken during product development. Part components need to be designed for the type of assembly that will be used. For heat staking, the plastic part will usually have a boss which is a feature that is raised above the surface. The mating part will have holes that are sized and strategically placed to meet up with the boss during assembly. The bosses will fit into the holes and will allow for heat staking to occur.
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[post_content] => Creating a successful injection molded component requires collaboration and the expertise of a skilled team. One of the most critical aspects of the design for manufacturing (DFM) process is selecting the appropriate resin. Choosing the right injection molding resin not only meets design goals and performance specifications but also aligns with budget constraints. By working closely with injection molding experts, you can engineer a solution that fits your needs perfectly.
Before diving into resin options, it's essential to clearly define the end goals for your product. Once these are set, you can narrow down the best resin choices. Here is an in-depth overview of the 12 steps to help you select the right plastic for your injection molding project:
Analyze Part Geometry
The size, shape, and wall thickness of the part can significantly impact its moldability. Parts with complex geometries or uneven wall thicknesses might be prone to warping, bowing, or other design issues. Early analysis using tools like Moldflow® software can identify these potential problems and suggest design modifications. For instance, resins like polypropylene (PP) are often used for parts with complex geometries due to their excellent flow properties and low shrinkage.
Define the Design Goals for the Part
Clarifying the main objectives of injection molding the part is crucial. Are you looking to reduce weight? For example, using lightweight resins like polycarbonate (PC) might be ideal. Are you trying to consolidate an assembly into fewer components or cut costs? High-performance engineering resins like polyamide (nylon) could provide the necessary strength and durability.
Describe the Key Physical Attributes Required
Understanding how the finished part will be used helps determine the necessary physical attributes. Does the part need high impact resistance, like acrylonitrile butadiene styrene (ABS)? Or perhaps it requires flexibility, where thermoplastic elastomers (TPEs) might be a better fit.
Describe the Environment in Which the Part Will Be Used
The environmental conditions the part will face can significantly influence resin selection. For example, if the part will be exposed to outdoor conditions, UV-resistant resins like ASA (acrylonitrile styrene acrylate) are ideal. For high-humidity environments, polybutylene terephthalate (PBT) is known for its moisture resistance.
Regulatory Compliance
Depending on the part's application, it may need to meet specific regulatory standards. For instance, if your product is intended for food contact, FDA-approved resins such as polyethylene (PE) or certain grades of polypropylene (PP) will be required. Similarly, medical devices might need to use biocompatible materials like medical-grade polycarbonate.
Desired Finished Appearance
The aesthetics of the part can also dictate the resin choice. If you need a high-gloss finish, materials like polycarbonate/acrylonitrile butadiene styrene (PC/ABS) blends work well. For a matte finish or specific texture, other resins can be textured during the molding process. Custom colors and decorative finishes can be achieved with additives and dyes tailored to the selected resin. Don’t forget that the ideal color can also be achieved by painting your parts after molding. It is important to understand cost advantages when comparing the cost of painting a neutral colored part to using colorants or custom compounded resins.
Identify Chemical Exposure
Chemical exposure during manufacturing, assembly, or end-use can degrade certain plastics. If your part will be in contact with automotive fluids, fuels, or cleaning solvents, a chemically resistant resin like polyoxymethylene (POM), also known as acetal, might be the best choice. For household cleaning products, using polyethylene (PE) or polypropylene (PP) may provide the needed chemical resistance.
Assess Electrical Requirements
If the part will be subjected to electrical loads, using a resin with good electrical insulating properties is essential. For instance, polyetherimide (PEI) is commonly used for its excellent dielectric properties. If electromagnetic interference (EMI) or radio-frequency interference (RFI) shielding is necessary, resins like polycarbonate (PC) can be combined with conductive fillers.
Evaluate Radiation Exposure
Parts exposed to radiation, such as UV light or gamma rays, need resins that can withstand such conditions. UV-stabilized resins like ASA are designed to resist discoloration and degradation from sunlight. For applications involving sterilization, resins like polyphenylsulfone (PPSU) can endure gamma radiation without losing mechanical properties. When the desired resin might not be ideal in this situation, painting the molded parts can be a consideration to solve this issue.
Document Size and Dimensional Tolerances
Accurate dimensions are often critical for the proper function and fit of parts. If tight tolerances are necessary, consider resins with low shrinkage and high dimensional stability, such as polyphenylene oxide (PPO). This resin is known for maintaining its shape and size under various conditions.
Note the Range of End-Use Temperatures
The resin’s properties can change dramatically with temperature. For instance, if your part will be exposed to both high and low temperatures, polyetheretherketone (PEEK) is an excellent choice due to its wide thermal operating range and excellent mechanical properties.
Estimate Production Volume
Understanding the number of parts needed helps determine the most cost-effective resin. For high-volume production, cost-efficient resins like polypropylene (PP) or polyethylene (PE) are often preferred. For lower volume, high-performance parts, investing in engineering resins like polycarbonate (PC) or polyamide (nylon) may provide the best balance of cost and performance.
By following these 12 steps, you can make a more informed decision in selecting the right resin for your injection molding project. Each step addresses a critical aspect of the product's performance and the environment it will encounter. Be sure to discuss this with your tooling design engineer to optimize your products.
To further simplify this resin selection process and ensure a smooth transition from design to production, Ferriot has developed an Injection Molding Resin Selection Workbook. Download your free PDF by clicking the button below and start your project off on the right foot.
Get the Resin Workbook!
Have some questions? Just Ask us and we would be pleased connect you with one of our experts to discuss them with you.
[post_title] => 12 Critical Steps for Selecting the Best Injection Molding Resin: A DFM Approach
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[post_content] => When creating custom plastic enclosures, whether for electronics, consumer products, or industrial equipment, the manufacturing process you choose profoundly impacts design requirements. One of the most widely used manufacturing methods for plastic enclosures is injection molding. However, the injection molding process has its considerations that designers must navigate to achieve functional and aesthetically pleasing results.
You may be developing an enclosure for a new consumer electronics device. Or the façade of a new electric vehicle (EV) charging station. Maybe it's next-gen emergency medical equipment used by EMTs and hospitals; it doesn't matter. Ferriot has a great deal of design experience with custom injection molded enclosures. When designing a new product, it is essential to consider several key factors when using an injection molded custom plastic enclosure, regardless of the final application.
The Ferriot team has years of experience in the custom injection molding industry. Logically, tapping their knowledge and expertise in new enclosure development makes sense. This article provides valuable insights into successfully completing your new enclosure design while balancing form and function.
Design considerations for custom injection molded enclosure design include wall thickness, ribs and reinforcements, corners and fillets, and undercuts
Considerations for New Custom Plastic Enclosure Design
The User Experience
Critical to the success of any new product is having a thorough understanding of how the user interfaces with the enclosure, the mating components used during assembly, how all the pieces and parts fit together, and how much interference or clearance exists in those areas.
If the equipment is to be serviced or maintained, the designers must determine where access to interior components is needed. This data enables the team to start thinking about the necessary tolerances and if there are areas of risk. Sometimes, the product designer needs to be sure of how things will work, or even if it will work, within the current design. Then, the team reviews the option of building prototypes to test these unknowns, especially for any risky areas. Prototyping is always a good idea to test the feasibility of the design before going too far.
Design for Manufacturing (DFM)
Tooling engineers will utilize your product design and inputs to design tooling to manufacture your enclosure. To optimize production and part quality, the tooling engineer must consider several design features for the mold, from gate placement to surface finish.
Gate Placement: Where It All Begins
The gate, the entry point for molten plastic, is pivotal in how material flows into the mold cavity. Gate placement is more than just a technical consideration—it affects material wastage, defect potential, and the part's visual appeal.
Defining gate placement in the custom injection mold design
Wall Thickness: The Key to Structural Integrity
Uniform wall thickness is a cornerstone of successful injection molding. It ensures even cooling and reduces the risk of defects such as warping and sink marks. Maintaining consistent wall thickness throughout the enclosure ensures structural integrity and contributes to a polished final product.
Strength in Ribs and Reinforcements
Enhancing the plastic enclosures' strength without compromising material usage is a challenge that can be addressed through thoughtful rib and gusset placement. By strategically adding ribs to specific areas of the enclosure, designers can prevent flexing, warping, and deformation, all while optimizing material distribution.
Smooth Corners and Fillets for Durability
Sharp corners might look sleek, but they often lead to stress concentration points and potential cracks. To mitigate these issues, incorporating rounded corners and fillets boosts part strength and reduces the risk of defects during molding.
Navigating Undercuts and Complex Features
Undercuts, or features that prevent part ejection, can complicate the mold design. Addressing undercuts effectively or designing them to be mold-friendly is a strategy that simplifies tooling and minimizes costs. This balance between complexity and manufacturability is vital.
Surface Finish and Texture: Practical and Aesthetic Impacts
The texture of the mold's surface transfers to the final part. Designers have the freedom to choose from an array of surface textures, but they must carefully weigh how these textures influence aesthetics, grip, and part release.
Material Selection: A Delicate Equation
Choosing the right plastic resin is crucial. In addition to necessary properties such fire or chemical resistance, one must understand how the resin reacts to the molding process. Different materials exhibit varying shrinkage rates during cooling and solidification. Designers must select materials compatible with the injection molding process and account for this shrinkage when determining dimensions. It is crucial to start the resin material selection process based on the standards and compliances your product must meet.
Material selection requires multiple considerations
One example: If you're designing a medical device that needs to be near or in an MRI machine, it cannot have any metal whatsoever in the enclosure, including any metal inserts. That could be very dangerous inside an MRI machine.
An additional consideration when designing a medical device enclosure is the importance of EMI/RFI shielding. Design engineers must take care to ensure that their device doesn’t emit signals and that it meets various EMI-RFI shielding standards. If reducing RFI through design isn’t possible, engineers can use an RFI-shielded enclosure as an effective solution.
RFI shielding can be applied internally to electronic enclosures as a spray. This coating spray is often used in plastic enclosures to reduce interference effects. (See Understanding EMI / RFI Shielding for Injection Molded Components to learn more.)
EMI/RFI shielding application to custom injection molded part
Once you have narrowed the resin selection, Ferriot’s supply chain team can work with you to determine its availability. The purchasing team researches where the materials are readily available, finding the best combination of price and delivery. We work hard to find the best possible price for the best quality materials that meet the enclosure's design criteria. It helps narrow the material selection, so we provide a list of the appropriate materials and let you, as the customer, make the final decision.
Striking the Balance of Mold Complexity
Complex molds with intricate features might unlock design possibilities but also increase tooling costs and production time. Striking the right balance between design complexity and manufacturability is critical to ensure feasibility and cost-effectiveness.
Integration of Assemblies: Beyond the Mold
A well-designed enclosure isn't just about what comes out of the mold. Designers should evaluate how different enclosure components fit together and how they can efficiently assemble them post-molding. Considerations include features like snap-fits, screw bosses, and alignment guides.
Tolerances: The Fine Print of Design
Though injection molding is extremely precise, it is necessary to account for variations in material shrinkage, mold wear and other factors during the manufacturing process that affect part size. Design and quality teams will determine acceptable tolerances which define the acceptable size variations for certain part features and overall dimensions. Tolerances allow for variation while ensuring that the part will still function and mate with other parts.
The Role of Moldability Analysis
Harnessing the power of computer-aided design (CAD) software to conduct moldability analyses is a smart move. This process identifies potential issues early on, allowing for necessary adjustments before the costly tooling stage.
FDA Requirements for Medical Devices
Understanding the FDA requirements for medical equipment is imperative to help decide the correct material selection and design controls. Then, knowing the product requirements, UL, flammability ratings, impact testing, and chemical and UV resistance is next. The product designer must prioritize these requirements, so the custom injection molder knows the most important ones. Then, our manufacturing engineering team will focus on hitting those requirements.
Summary
As you can see, developing a new enclosure requires much consideration. Designing plastic enclosures for injection molding is a delicate balance between aesthetics, functionality, and manufacturing feasibility. The considerations outlined are essential guideposts that steer designers toward creating enclosures that look great and result in efficient production using injection molding. Collaboration between designers, engineers, and manufacturers is the key to unlocking the full potential of this manufacturing process while delivering exceptional products to end-users.
The Ferriot team is here to support you in developing the right enclosure design that provides the proper form, fit, and functionality in a highly durable and attractive package. Based on the part geometry, complexity, and numerous other design factors, we work closely with you to develop the best custom injection molded solution for your new product’s design.
Learn more:
Want to learn more about metal to plastic conversions? Discover how we tackled complex challenges when a fuel pump original equipment manufacturer (OEM) was seeking savings through a durable plastic conversion here.
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[post_content] => Customers often ask us, can you paint plastic molded parts? The answer is yes, although painting molded plastic requires specialized knowledge, the proper equipment and an experienced staff. Special paints are required to give your parts the desired finish and ensure the paint bonds well with the plastic. However, painting techniques have evolved over the years and there are several different means by which the plastic parts can be painted to meet any need.
Molded plastic is typically painted using a multi-step process that involves surface preparation, primer application and topcoat painting. The plastic surface is cleaned and treated to ensure paint adhesion, followed by a primer application. Finally, the desired topcoat paint is applied in layers, before curing. Curing creates a durable, attractive finish.
There are two main reasons why painting molded parts provides a benefit to the customer:
Example 5-color digital printing on custom injection molded medical enclosure
Digital printing allows for unlimited color options (Source: Engineered Printing Solutions)
Example of digital printing on larger injection molded parts (Source: Engineered Printing Solutions)
Due to digital printing’s large print area, it is possible to print on multiple parts simultaneously (Source: Engineered Printing Solutions)
To try to produce this one 28-gram part out of this large tool, with plastic that sits in the barrel for hours and hours, it's just not possible to do. So, we learned the hard way that we could only produce this part within spec by sacrificing a larger part to get the proper material flow into the tool we needed. And that raised the price of this part from approximately $2 to $10, which our customer was not happy about.
Liz: Are there common shortcuts that mold makers take that our customers should be aware of that, "Hey, be careful if somebody says, 'We're going to do it this way,' because this can get you into trouble or can cause a problem in the future"?
Amy: Well, there's just a lot of unknowns until we receive the transferred tool. We request drawings or 3D models of the tool in advance. However, we always need to find out if we're getting the most updated version of that tool's drawings and models. It's common for the tool design not to be updated as the part design gets updated. So, we only know what we have once it gets here at Ferriot.
Liz: Really? The physical tooling could have been changed, and the spec drawings or whatever were not changed to reflect that?
Amy: Absolutely. It can be a revision control nightmare.
Liz: What is the most common reason a mold owner would arrange to transfer their mold tooling?
Amy: We often don't know. The mold owners often don't want to be transparent with us about the problems they're having with their current supplier. They're either experiencing quality issues, delivery issues, costing issues, or a combination.
Jerry: Agreed. It's usually because either the customer is having trouble with their current supplier's quality, delivery, or something else, or the current supplier just has told them they want to get rid of it. One of the parties is having trouble and needs to move the tool.
Liz: What are some reasons the current supplier would want to get rid of it? Slow-paying customers, things like that?
Amy: Low volume orders, price issues, or too much scrap.
Liz: We've also done that, where we've told customers to take their tools elsewhere. Many times, these might be legacy customers moving on to new products and suppliers, and we're being used to produce service parts for the old products. We've lost the business, and it's not worth our effort to continue to run small orders for them, and it's ending a business relationship.
Who are the key players on our Mold Tool Transfer Team? Then, beyond the project manager, who do you typically work with on the customer side?
Jerry: It works best to involve the customer's project manager, product engineer, and quality engineer. We need the complete history of the tool, how it's designed, and the product requirements. It doesn't work well when the only person involved on the client side is the purchasing procurement people. They tend to know little about the tool, the part, or anything else; they're just trying to get the business transferred. Period. And they don't know anything technical about the tool, nor do they know much of anything about the finished part.
Amy: Optimally, our team typically includes the project manager, tooling manager, quality manager, and a process engineer. That is ideal.
Liz: A great deal of these processes’ hinges on good communication. There are also a lot of details that need to be reviewed, revised or even replaced with process improvements. It's a lot of servicing the business relationship.
Jerry: Absolutely. Another excellent example of a tool transfer that went well is the tool that came from Swaco. Amy would agree with me. It was a lot of work and effort, but we had all those people pretty much in alignment. We had their process engineer; we had their support from their engineering and quality organization. We knew what we were getting—no hidden problems. We could talk back and forth many times to get the tool up and running. It went very well, and we have a profitable product that we're able to ship them parts.
Amy: That is a good example, Jerry. Initially, there were some growing pains, but you're right; the customer was very supportive. They have injection presses of their own, so they're very familiar with injection molding, which helps tremendously. They were willing to come on-site and help us evaluate the first production parts. They've been very good to work with because they have molding experience.
Liz: Were you guys involved more on the front end before the decision in this case? Or was it just good to have those people helping you after the decision was made?
Jerry: There was good front-end support when we were quoting the receipt of the tools. So, we had a reasonably good idea of what we were getting. But then, to Amy's point, what helped was, when the tool came, we had access to their process engineer, product engineer, and quality engineer. And we worked as a team to get it up and to run and resolve the issue. There was no shortage of work to do and no shortage of effort, but it all went very well because it was a team effort.
Jerry: On other transfers, the buyer arranges them.
Liz: I can see it is difficult because if you're getting a tool from another injection molder, they're either happy to see it go, or they're not happy to see the business go. As a result, you don't necessarily have access to the necessary assistance either way.
Amy: Definitely. It's a tricky business for customers to get information from their supplier that they've never asked for before, like mold designs, process sheets, and things like that. That throws up some flags with their current suppliers, and it sure would if it was asked of us. And there can be a reluctance to share that information for whatever reason.
Liz: Is it a suggested best practice for OEM mold owners to request that information from a molder when they start doing business and setting up new tooling as a form of risk mitigation?
Jerry: I think it's typical. If our customer asked us to provide the mold design, we certainly would do that because they own it. There's no question about it. If we built them a mold, they would own it. We provide them with the design, the 3D CAD, and everything if they want it. However, providing the process sheets, that's different. We'd have to think about that. How important is the customer? That is proprietary information to us. That's how we run that tool. But we'd likely ultimately provide it, especially to a large important customer who understands molding operations.
Liz: Yeah. I could see a company; even if they're going to stick it in a file somewhere, it's just part of owning the tool and mitigating risk just to have the information.
Jerry: Correct. We sometimes run into a problem when a customer is transferring tools to us. If they have it at a different molder, they're sometimes reticent to get the mold design and process information from their current supplier because that would be tipping their hand that they're just about to move that mold.
Summary
Mold tool transfer projects can pose unique challenges, with one of the main difficulties being the unknowns that come with receiving a transferred tool. While OEM mold owners can request drawings and 3D models in advance, there is no guarantee that they will receive the most updated version of a tool's design over time. This issue can lead to problems with producing parts within spec, as well as revision control nightmares. Good communication is critical, and it is essential to have a team involved from both the mold owner's and supplier's sides, including project managers, product engineers, and quality managers, to mitigate these risks.
In part three of this article, I’ll review a few additional mold tool transfer success stories with our team of experts. We will discuss some challenges that we faced with our customers, how we addressed those challenges, and the end results that Ferriot’s solutions team delivered.
To learn more about mold transfer considerations, download the "Mastering the Shift: 7 Key Points for Smooth Injection Molding Supplier Transitions“ white paper.
[post_title] => ShopTALK: Mold Transfer Considerations Everyone Should Know
[post_excerpt] => At Ferriot, we’ve identified seven key points you should consider before making a tool transfer, including everything from inventory to cosmetic standards.
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[post_content] => Mold transfer, beginning with the RFQ phase of the tool transfer inquiry, sharing full transparency throughout the transfer process for efficient and effective tool transfer with your new custom injection molding supplier is essential. Therefore, it is necessary to clearly define the project scope and the responsibilities and expectations of everyone involved.
Before moving forward with production, any tool refurbishments should be quoted and submitted for approval. The required validation processes and protocols should be defined and agreed upon prior to execution by the supplier.
[post_title] => Are you ready for your mold transfer? Tool Transfer Success Checklist
[post_excerpt] => Providing complete and accurate information for your mold transfer helps assure the smooth, timely, and cost-effective transition. Here's what you need.
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[post_content] => Making the decision to move injection molds from one supplier to another can be a daunting task, not for the faint of heart. The saying “the devil is in the details” is very apropos to the mold tool transferring process. If you don’t cover all the necessary details, you may be jumping from the frying pan into the fire. At Ferriot, we’ve identified seven key points you should consider before making a tool transfer, including everything from inventory to cosmetic standards. It takes communication, transparency, precision, and above all, experience. We hope these recommendations help you with a successful transition.
Before we proceed with our ShopTALK discussion, we recommend reviewing our whitepaper Mastering the Shift: 7 Key Points for Smooth Injection Molding Supplier Transitions. Our conversation with Jerry Graf and Amy Mathia will investigate some of these considerations.
Jerry Graf is the Manager of Engineering. Previously, we spoke with Jerry about how mold flow analysis and tool design impact injection molded part quality. Discussing mold tool transfer considerations is a natural extension to that conversation.
Amy Mathia has been with Ferriot for over seven years as an Engineering Project Manager who works closely with the customers, our tooling engineers, and the production department on new product development. One of Amy's main goals is ensuring projects are within budget, and her experience includes some rather challenging mold tool transfers.
Liz: In addition to the white paper that I mentioned earlier, how does Ferriot help customers feel comfortable that, when they transfer their mold to us, we can hit the ground running?
Jerry: We use a checklist, a guide for transferring tools. Engineering also has an internal checklist that we would go through upon receipt of the tool to ensure it is clean, properly maintained, and ready for our production floor. It's very similar to the checklist we would go through when we receive a new tool we built or had built for us. With the checklist, a prospect can go down the list and say, "Yeah, okay, I've got all of this lined up, so I now can proceed with a higher degree of confidence.”
Liz: Why might a mold owner want to stay with their current supplier?
Amy: As we’ve learned about tooling problems, quality issues, and so on, we had to tell prospective customers, "Here are some of the headaches you're going to have." We don’t sugarcoat it because it can become expensive to correct these problems.
Jerry: And it can go both ways. Because on the saes side, we're interested in earning more transfer business, but on the engineering side, it (often) creates many, many headaches for us. So, when talking to a potential customer about clear and obvious issues, we must ask them, "why would they want to do it? Is it worth it? Why should they not want to do it? What are the options?
Liz: So, it is important to know ALL the “why’s” when it comes to a pending transfer?
Jerry: Yes, that is one of the critical questions. Making sure we're talking about some of the (possible) headaches, one of the key questions to ask when taking on a transfer tool is, "Why are you transferring it?" More often than not, it's because they're having trouble with it.
Liz: And what kind of trouble are they having?
Jerry: Frankly, if a customer transfers the trouble, that's moving it to a different spot; it isn't solving the problem. So, we need to have a frank, open, and honest discussion about what is wrong. Why are you (really) transferring it? Why do you want to transfer it?
Liz: After you find that out, do you ever say, "Well, you probably shouldn't transfer because we may not have the answer for you." Or do you confer amongst the engineers at Ferriot for a solution?
Jerry: After assessing the situation, once we know the problem or problems, we often tell them, "Well, yeah, we can help you with that. We can help resolve that situation. And here's what getting this mold into the proper shape will cost."
Another bad reason to move it is that the tool is old and worn out, and your current supplier can't provide quality and can't maintain production. But if the tool is old and worn out, neither can we. If there's something wrong with the tools, that must be taken into consideration either before it's transferred or as it's being transferred.
Liz: What are some good reasons to do a mold tool transfer?
Jerry: A good reason for moving a tool would be you're moving it for logistical reasons. For example, you're getting it closer to where it needs to be from a manufacturing or distribution perspective, so you're not shipping the finished product so far. Or you're moving it to a supplier with superior capabilities to run the part.
Amy: To be perfectly honest, I'm not a big fan of transfer tooling. It's okay to be blunt about it. Typically, the reason is it's a problem somewhere else, and our customers want to move that problem. And when our biggest customers ask us if they can do that, we can't say no. However, one of the best reasons I have heard of in my experience for moving tools to Ferriot would be the value-added things we can do here—for example, painting parts. If a mold owner has a part being molded by another supplier, and then they must send the parts somewhere else to get painted, additional costs are obviously involved. So, one good reason for transferring to Ferriot is that we also print and paint parts. Those are just two of the value-added things that we do. But in general, when someone is looking to transfer tooling, it's a problem somewhere. Tools aren't being moved because everything is running beautifully. It just doesn't happen that way.
Liz: Yeah. Like Jerry said earlier, they're just looking to move the problem and that's not always a solution. However, we can work with them to find a solution.
Amy: Absolutely. Another thing that could be a good and a bad reason is capacity. Your current molder might not have the capacity, and you might find a molder that has the capacity and can speed up your lead times.
Jerry: Yes. That would be another good reason to move the tool. It is a reason that would not be necessarily problematic if you're looking for a supplier that has additional capacity, additional capabilities of any sort, as Amy mentioned, finishing capabilities, capacity capabilities, maybe some processes that your current supplier doesn't have because they're more of a shoot-and-ship shop. And just trying to consolidate that all in one place. Those are reasonable reasons to want to move the tool.
Liz: With the recent increases in fuel costs, are you seeing people interested in transferring molds because of the shipping costs?
Jerry: Yes. We're seeing customers bringing tools here from Asia because of the problems of getting parts across the ocean. They're re-shoring some tools into North America.
In part two of this article, I’ll review addition tool transfer considerations as well as a few mold tool transfer success stories with our team of experts. We will discuss some challenges that we faced with our customers, how we addressed those challenges, and the end results that Ferriot’s solutions delivered.
[post_title] => ShopTALK: Mold Transfer Considerations Everyone Should Know [post_excerpt] => At Ferriot, we’ve identified seven key points you should consider before making a tool transfer, including everything from inventory to cosmetic standards. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => mold-transfer-considerations-everyone-should-know [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:08 [post_modified_gmt] => 2024-03-11 20:11:08 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-mold-transfer-considerations-everyone-should-know/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [16] => WP_Post Object ( [ID] => 2260 [post_author] => 3 [post_date] => 2023-07-14 13:00:00 [post_date_gmt] => 2023-07-14 18:00:00 [post_content] =>
In our previous article, Is it Time to Break Up with Your Custom Injection Molder?, we addressed missing deadlines, cost overruns, and quality issues as three primary reasons for deciding to move to a new supplier by transferring your mold tools.
However, before making such a significant leap of faith, you must be careful not to jump from the frying pan into the fire. As a first step, take time to understand the "Mastering the Shift: 7 Key Points for Smooth Injection Molding Supplier Transitions."
While it seems common sense that the most critical key to success is maintaining complete transparency throughout the transfer process, it is surprising how many times that does not happen. Understandably, to accomplish that level of transparency, open and honest communications must exist between the mold owner and the potential new supplier. The harsh reality is that, sometimes, the mold owner can be the source of their headaches through miscommunications and "errors of omission" (intentional or unintentional).
At Ferriot, we have been managing mold tool transfers for many years and pride ourselves in meeting and exceeding client expectations when we deliver finished parts to these clients. However, we've had some mold tool transfer challenges over the years and experienced several things that cause mold transfers to not work out so well. We know that if a customer wants to move a mold to us, it is usually not for a good reason.
Reasons can include:
Ultimately, everyone looking to transfer a mold wants to be completely satisfied with their finished product in every way, but for some reason, they are not. That's why we're here. Being open about any existing mold tooling problems and understanding the need to invest in corrections or improvement are two things that cannot be ignored.
Many problems begin when the company transferring the mold is unwilling to invest the money necessary to make the necessary corrections or improvements.
However, as is the case with most business challenges, the problems are rarely one-sided. For example, ask any custom injection molded parts customer whether they have had issues with a molder, and they laugh at the thought. Some may even respond, "Too many!"
Despite the issues, for many mold owners, even the thought of moving work is a tremendous pain, and there are numerous reasons to avoid it. For example, forecasting the current and near-term demand and then building a bank while keeping it from the current molder. Then, there's paying to move the tool, hoping it is not damaged in transit. Assuming the tool makes it successfully in one piece to the supplier, there are the costs and time associated with requalifying parts at the new supplier. Some decide, "Maybe it's better to stay with the devil I know than move things to the devil I don't."
At Ferriot, we understand these concerns, and our Mold Tool Transfer Team works very hard at maintaining transparency and keeping the lines of communication open, knowing that the devil is, in fact, in the details. More and more mold owners have learned that transferring their molded parts requirements to us is wise; we specialize in highly engineered custom parts with highly engineered resin. In our tenth decade, experience has taught us the accurate and fair cost of providing parts to customers on time and to exact specifications.
And that brings us to the biggest headache: After all the time and effort, some companies look at the tooling and piece part price only. Awarding work this way can be a mistake. Understanding the lifetime value of the tool is important as well as the details on how the molder came to their pricing. Also once you have selected your molder, the DFM phase is where some part redesign will more than likely be needed. Collaboration with a team you can work well with is key. The most important work is done up front and will save money in the long run.
However, we know that will be the first and not the last we hear from many mold owners. They eventually realize their mistake, and after tens of thousands of dollars and tons of angst after a year or so, they call us to help fix it.
Ferriot can fix it, but if you want to save money and hassle, trust us up-front. Or trust us later.
[post_title] => Headaches to avoid when transferring a mold to a new injection molder
[post_excerpt] => Before working with a mold tool transfer company, here are a few headaches to avoid.
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[post_content] => Injection molding is a widely used manufacturing process that produces plastic parts in high volume. Multiple industries rely on this process, including medical, electronics, automotive, agricultural and consumer products, to name a few. This highly efficient manufacturing method has a projected CAGR of 5.1% through 2027, for a potential market value of $240.9 billion.
During injection molding, molten plastic material is injected into a mold cavity, allowing it to cool and solidify. When cooled, the parts are ejected. However, certain manufacturers new to the process might cool to the idea of injection molding after investigating the startup costs.
A careful examination of key phases of this process can help manufacturers more successfully navigate this cost challenge. These can include the total cost of ownership, the importance of resin selection during the planning phase, design for manufacturability and secondary operations. This examination can help determine whether injection molding is a viable alternative for a new project proposal and will supply the desired return on investment.
Total cost of ownership (TCO) represents a crucial metric in manufacturing that considers all the expenses associated with a product or part over its entire life cycle. For injection molding processes, TCO includes costs such as the price of the mold or tooling costs, the cost of the particular resin specified for the part, and the average cost of manufacturing as a price per piece basis over the projected product lifecycle.
The cost of the mold can be significant, and it is essential to consider its expected lifespan and the volume of parts it can produce, to calculate its actual cost. The price per piece is calculated using factors such as the material used, the part complexity, the number of units produced per run and the setup costs associated with each individual run.
Finally, resin costs can represent up to 50% of the total part cost. Resin choice impacts a variety of factors per project. For example, when the part is required to withstand exposure to UV rays or needs chemical resistance capabilities, this will restrict resin choices to thermoplastics that offer these characteristics.
The higher cost of setup and tooling associated with injection molding compared to other plastic technologies often restricts the process to companies that make parts with larger volumes, from the thousands to the millions. Certain specialty parts in smaller quantities that meet a specific market need also take advantage of injection molding. Tooling, resin selection, part quantities and overall volume over the course of two to three years can supply manufacturers with a reasonable expectation for total cost of ownership to compare pricing.
When it comes to selecting the right resin for injection molding, there might not be a more crucial factor impacting the project cost. The resin itself often dictates conditions of tooling or mold making. Molds are constructed according to mold flow analysis of the resin choices and desired properties. Once this mold flow analysis is conducted and the tooling created, its performance is linked to the specific resin analyzed for that mold.
Factors involved in resin selection will include the material’s:
For example, when producing injection molded parts destined for use on gasoline dispensers and pumps, the resin must exhibit a high resistance to the chemicals present in gasoline.
Resin costs typically account for approximately 50% of the total project cost. Prior to making the mold or tooling, companies new to injection molding can consult with the engineers at an experienced partner such as Ferriot, to discuss resin alternatives based on the properties desired in the finished product.
Engineered resins can cost as much as $10.00 per pound or more, while lower-cost commodity resins like PVC, polypropylene, or high-density polyethylene can be less expensive. The best time to determine resin options is early in the planning stages.
Part of resin selection is also looking at resin availability, location of the producer and/or distributor(s) and lead time. Resins that are more widely used pose less supply chain risk. One might consider supply agreements for highly specialized resins or blends. It is also suggested to qualify more than one resin in the tool as a backup to provide insurance against any future supply issues.
The cost of tooling is a critical factor in the injection molding process and can vary widely depending on the size and complexity of the mold. While purchasing tooling from vendors in the Pacific Rim may offer cost savings, manufacturers also need to consider all factors involved with ordering tooling from overseas.
There is typically a longer transit time for overseas tooling that can stretch from eight to twelve weeks for oceanic shipping. Some customers will cover the cost of air freight to reduce lead times, although this adds to the expense.
There are additional concerns about intellectual property being compromised, particularly when dealing with vendors located in countries like China, Vietnam, or Korea.
Alternatively, tools made in North America, particularly in the US and Canada, are more expensive but offer a quicker turnaround time and greater assurance that intellectual property rights will be protected. Companies in highly competitive markets where proprietary business practices weigh more heavily, such as medical instrumentation, electronics and semiconductors for example, are most concerned about protecting intellectual property. Manufacturers must carefully weigh these factors when considering the cost of tooling and where that tooling is created, for risk mitigation and as part of total cost of ownership.
The cost of the mold is one of the biggest barriers for market entry for some startup companies. Someone new to injection molding might not be aware that the mold can cost anywhere from $30,000 to more than $600,000 depending on the size.
Another design option to lower costs over time for projects with large production runs is to consider a multi-cavity tool. This allows multiple parts to be produced at a given time. The initial cost of a multi-cavity mold might be higher than a single cavity; however, this can be amortized over the mold's life.
After the tooling, when creating or producing a product run, there are the injection molding machine cost which includes utilities, labor and setup. This typically comprises 30% of a project cost. The setup is a fixed cost and remains the same regardless of whether a customer produces one or one thousand parts.
Additionally, the production lot quantity is another cost bucket, which refers to the total quantity of parts produced in a single production run. Ferriot often runs on a 60-day cycle, producing the quantity required by a company for that time period. This balances the setup costs and labor with warehousing and storage.
The size of the production run can help amortize the setup costs, or the labor involved in installing the mold into the press. Certain molds might take an entire day to set up. In other cases, a heavy mold of 40,000 pounds for example, might require an overhead crane to move into position. Mold set up requires time and takes an experienced, sophisticated team.
A better understanding of these cost components can help manufacturers make well informed decisions to optimize production and reduce costs.
One of the key advantages of working with Ferriot is its ability to offer a wide range of finishing operations all under one roof. This reduces the complexity of the supply chain for customers that might otherwise need to ship parts to multiple locations for services such as painting, pad printing, or the insertion of metal components.
Ferriot has built a reputation in the industry for these services and most customers take advantage of these finishing operations. A comprehensive approach to plastic part fabrication can help save customers time and money by streamlining the production process.
The engineering team at Ferriot is also available to consult on design for manufacturing (DFM). Typically, the customer will specify a resin preference according to the design brought into the shop. On occasion, the part’s design will not suit the injection molding process. The Ferriot team can supply suggestions for design modifications when drafts or undercuts might limit the ability of the part for injection molding.
Companies of all sizes trust Ferriot for injection molding and value-added finishing services. The company makes every effort to overcome supply chain issues by leveraging its relationships with multiple suppliers. By investing in spare parts to keep machinery in top working order and increasing its stock of resin, Ferriot can help customers maintain project timelines. Call Ferriot today to discuss your next injection molding project.
[post_title] => Navigating the Cost of Injection Molding: Factors to Consider [post_excerpt] => An examination of key phases of injection molding can help determine whether injection molding it's a viable alternative for a new project proposal and will supply the desired return on investment. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => navigating-the-cost-of-injection-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:08 [post_modified_gmt] => 2024-03-11 20:11:08 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-navigating-the-cost-of-injection-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [18] => WP_Post Object ( [ID] => 2262 [post_author] => 3 [post_date] => 2023-03-01 15:16:00 [post_date_gmt] => 2023-03-01 20:16:00 [post_content] =>
Problem: Ferriot needed to find a way to produce a high-mix, low-volume portfolio of parts for its customers without requiring two or more operators on every job.
Solution: The combination of cobots and vision systems was quickly adapted to handle a wide range of custom injection molded parts.
Dave Tillett, editor at Plastics Machinery Magazine, in a recent interview with Jeff Hodnick, an automation engineer at Ferriot, learned how Ferriot turned the problem into an opportunity and ultimately developed their solution.
By using cobots in coordination with vision systems, Ferriot can handle tasks that formerly required human operations to perform mundane tasks repeatedly. After implementing its new automation processes a few years ago, Ferriot can better utilize its workforce more efficiently to perform essential tasks, resulting in better quality control and efficient expediting of deliveries.
Ferriot is putting cobots into service in some very unique ways. “The easiest task for a cobot is pick-and-place stuff,” Hodnick said. “From there, it kind of evolves up into where we actually put Dremel tools to use a cobot almost like a CNC. Worked phenomenal, too.”
Ultrasonic welding is another job the automation department tackled. “We use parts underneath an ultrasonic welder with one cobot. We had to come up with some of our own proprietary stuff to pull it off, but we were able to.”
Read the full article from Plastics Machinery Magazine to learn more.
Learn more:Automating Injection Molding Processes Improves Efficiency: Cobots & Vision Systems
Automating Injection Molding Processes Improves Efficiency: 3D Printing End-of-Arm Tooling
Ultrasonic Welding: What Designers Need to Know
Importance of TQM to Injection Molding Projects
In our last article, I spoke with Jeff Hodnick, our Automation Engineer, about how Ferriot is integrating new automation technologies, such as 3D printing and custom end-of-arm tooling design. Previously, we outlined how Ferriot utilizes cobots to enable more efficient manufacturing in injection molding.
In this installment, Jeff shares additional details on how Ferriot uses the latest cobots and vision systems to strategically enhance the Ferriot workforce while increasing throughput and assuring quality.
Liz: A few years ago, we wrote about how Ferriot used our new cobots in manufacturing. Since then, you've been utilizing them even more. How are you using them lately? What are some of the things our people can now do instead of the processes the cobots are taking care of?
Jeff: So right now, we have one that does some of the dual plastic-on-plastic welding out in our molding department. And then we also have another one where we rotated between an ultrasonic welder and a pad printer back in our finishing department.
In all three use cases, it's allowed us to take what would be a two-to-three-operator job and bring it down to one. Plus, we have our insert welder on a cobot. Using that approach, we can weld and move the part around approximately three times faster than a typical human operator—without the fatigue a person would experience. As a result, the new approach frees up space and at least one person on everything we deploy to the cobot.
We're in the process of evaluating the addition of two more cobots to our operations. I'm working on the justifications and planning out the required first deployment steps.
Liz: Since you're looking into more, how much has the cobot technology changed since you bought the first two?
Jeff: Technology has continued to move forward and become more sophisticated. More than anything, they've become even more reliable. There are more options from which to choose. We're evaluating several different brands; most have auto-synchronizing features. For us, rapid deployment, changing molds all the time, being able to quickly move a robot right in front of a belt and synchronize all the accesses and be able to deploy it within 20 to 30 minutes is huge. I've been to the Automate Show in Detroit, which is the largest robotics and automation show in North America. As far as technology changes, we are seeing more reliability and flexibility. All the cobot technologies are making significant strides. Everything is so much more reliable. Conversely, I wish I could say it was easier to get spare parts, but we all know how supply chain issues are right now.
Liz: What are some of the other benefits of cobots?
Jeff: One of the most significant benefits is protection and shielding requirements are minimal. You don't necessarily have to build a large cage around them. Don't misunderstand. You still have to put up some protection whenever you're using cutters, grinders, and stuff like that, in conjunction with them. But, for the most part, they're pretty hands-off. The second they touch anything else that they're not supposed to, they stop almost right away. They're outstanding about all that. There's a whole lot more intelligence there than there used to be.
Liz: When it comes to the companies that make the cobots, they tend to tout the value prop that your people can do something else, and that's kind of vague. Let's be specific. At Ferriot, what can our people do instead because the cobots are now performing these functions?
Jeff: Primarily, we can simultaneously have more active presses because, instead of needing two or three operators dedicated to a single press to run a job, you only need one. This approach results in better labor dispersion, where we can run more presses since we have the people to run them, and we can better deploy our people to the most active, time-sensitive projects. This provides great cost improvements due to lower labor overhead and allows us to help our customers save on part cost.
Additionally, I'm working on a project with the two new cobots I mentioned earlier where we'd be able to have them handle a lot of parts processing. So, all we need people to do is walk between presses and handle packing the parts.
In cases where we're doing all the post-processing with the robot, we classify it as half an operator because the operator doesn't have to wait an hour for parts to be processed. They can split their time between two to three presses at once, packing the parts once they reach a certain quantity at each of the presses. So, it improves our efficiency and labor dispersion.
Liz: How are we using the vision systems along with the cobots?
Jeff: The vision systems are another technology that, while they've always been around, the ease of programming and implementation has recently improved in the last few years. Today, these systems are much more flexible, and easier to use. While we have three systems, we actively use two as part of our quality control.
Imagine a part that takes a hundred (or more) inserts, and because there's such a low volume run, we can't automate it. As a result, sometimes an insert or two isn't put in place properly. In situations like that, we have a vision system that'll check both sides of a part.
We have smaller vision systems that have hot-swappable nests. So, you can use the same exact system, switch between programs and check for a multitude of parts simultaneously. Being able to universally adapt vision systems has been a huge win for us.
Liz: How were those processes handled before having the vision systems?
Jeff: They were mostly manual, dependent on our quality inspectors, Very time and labor-intensive.
Liz: And so, with the use of the vision systems again, like the cobots, those people that used to do those labor-intensive jobs that took a more extended period of time, what are they now doing?
Jeff: Again, it's about strategically dispersing the personnel. We have those vision systems in our finishing department. So instead of only running one or two different parts to that department a day, we're currently running four to five different parts—with different things being worked on widely across it—and sometimes it's even more than that. Our wider dispersion of labor, enhanced with an automation workforce, enables us to get more done, more accurately, with greater throughput and quality assurance.
Liz: In summary, what the cobots and vision systems do for our customers is they bring that consistency that no matter how hard a human being tries, they just can't do. At some point, the human operator gets fatigued.
Jeff: Exactly. The robot sub stand eliminates that issue while saving time. We even have instances where we've put vision systems and inspection systems on the end of a cobot.
Liz: How does that work?
Jeff: We created a custom end-of-arm instead of the normal extruded aluminum. We made it out of a solid piece of aluminum, but we were able to mount a couple different sensors and wire them that way. By doing that, we were able to create a tray where an operator sets a part and then presses a button. A button is only required when we need to ensure the operator is out of the way. Once they hit the button, the robot will individually check for each insert, it'll check depth gauges in key areas, making sure everything is in the correct positions. The robot extends over top of the entire part, completing the whole inspection.
An example is retail fueling dispenser bezels. We’re using the robot and vision system combination for inspection. Basically, the operator sets the bezel, also called the front housing, onto the fixture. Then the robot goes through and inspects each part of it, making sure everything is in correctly. There are secondary sensors as well.
Automation using cobots and vision systems are tools Ferriot uses to streamline processes which improve productivity and save labor overhead cost. These efforts ultimately help to minimize part cost and improve throughput.
[post_title] => Automating Injection Molding Processes Improves Efficiency Part 2 [post_excerpt] => Cobots & Vision Systems for Custom Injection Molded Parts [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => automating-injection-molding-processes-improves-efficiency-part-2 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:08 [post_modified_gmt] => 2024-03-11 20:11:08 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-automating-injection-molding-processes-improves-efficiency-part-2/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [20] => WP_Post Object ( [ID] => 2264 [post_author] => 3 [post_date] => 2023-01-23 14:34:00 [post_date_gmt] => 2023-01-23 19:34:00 [post_content] =>Ferriot works hard to provide high-quality custom injection molded parts while remaining cost-effective and delivering on time. That's no small task, and one of the ways we do this is by utilizing many class-leading technologies in our custom injection molding operations. In previous articles, we've discussed everything from robotic arms and inspection scanners to mold flow analysis.
In my latest interview, I spent some time with Jeff Hodnick, our Automation Engineer, to learn more about his role at Ferriot. Jeff's been with us for the past three years, putting his nearly decade-long engineering experience to work on behalf of our customers by integrating new automation technologies to streamline processes and improve efficiencies.
Liz: Tell me about the different automation technologies that you get to use—like 3D printing and cobots. How is Ferriot using them?
Jeff: A large portion of what we do with 3D printing is fixturing. Primarily we make a lot of nests and related items, like how many companies fabricate them with resin. At Ferriot, we will design the nests in CAD using programs like SolidWorks and then do a 3D printout instead. So, we can use nylon and more robust stuff like carbon fiber-infused materials to get the same strength with less weight. We're tinkering more with end-of-arm (EOAT) stuff and 3D printing, but not too heavily; we've only made Gripper fingers and brackets so far. We saw some success with it, but the use case is primarily for nests and fixturing.
Liz: How does the end-of-arm tooling work as it relates to the 3D printer
Jeff: Right now, we use EOATs, the tools that go on the end of robot arms, to pick parts out of the injection molding presses. In some cases, some parts are hard to grab, and you must go at it from a specific angle, and there's no flat surface, but you still need to be able to grab the part out of the press. We can custom design whatever gripper type we could ever need, and 3D print it Then we're able to go in and grab parts that way. We buy grippers without any actual fingers on them, then design and print what we need for the specific application.
We would use them primarily for stuff like that. Or if it's a small, confined space, we must use a really small gripper, but the part is wide for that space, then we will use them in that regard too. It's kind of like boosters to go out wider to grab the part.
The significant advantage of being able to 3D print for EOA tooling is the customization and flexibility that it offers. It eliminates or at least reduces any restrictions we may have had before because of space issues. If we can mold the custom part in our machine, we can get it out with our custom designed EOA tools.
Liz: What are some of the limitations you run into with off-the-shelf EOA tooling?
Jeff: The limitations are size-related because they have standardized stuff that works for probably 75% to 85% of typical applications. But as soon as you get into the more custom molded part designs, that's when the 3D printing EOAT capability really shines. And Ferriot specializes in custom injection molded parts, so it's important to us.
Liz: Most of us are familiar with the grippers and suction cups at the end of a robotic arm. Can you give me an example of a custom EOAT that you might need to create?
Jeff: Yes, the suction cups and grippers are your standard go-to stuff. And they work for 90-95% of things. It's just that small 5-10% of the stuff that has no flat surface where the standard EOA stuff won't do the job. I would have to say that the majority of the 5-10% are angled parts—where the pieces come out (of the press) at an angle, and there's no flat surface, so you can't use suction cups, you can't use standard grippers, or the gripper might mar the part's visible surface—different situations like that. So, being able to bring custom EOA tooling designs to life, that's where 3D printing can be a huge help.
Liz: Besides giving Ferriot the flexibility to create the customized parts that our customers might need, do you use 3D printing for anything else?
Jeff: In addition to the custom EOAT tooling, we also use the 3D printers for our quality department, making tool holders and organizers, and stuff like that. Because it's quick, because they have a lot of specialized tools that are outside the norm shape wise
Liz: Rapid prototyping?
Jeff: Kind of, but only internally, more like rapid deployment as part of our process. The quality team has a lot of specialized tools and stuff that they use for specific customer projects. For us to be able to make a container for them to store it in, and do so quickly, that's ideal. You're looking at five times the cost if you were to have one of those things custom-made for it. That's a significant cost-saving measure for Ferriot, and it's customers.
In the next installment, I will talk with Jeff about how Ferriot combines our cobots and vision system technologies to further automate our custom injection molding processes.
How do Mold Flow Analysis and Tool Design impact injection molded part quality? [Part 1]
New Scanner Adds Color and Clarity to Injection Mold Inspection Data
Cobots Enable More Efficient Manufacturing in Injection Molding
Consider this scenario: Despite your best efforts, your custom injection molder continues to miss critical deadlines or is producing and assembling your project at an unacceptable error rate. Bottom line: It costs you much more than you had budgeted and has become a problem that needs to be fixed.
What are your options? Can you afford to switch to a new manufacturing partner?
Many companies choose a supplier to provide custom injection molding services, finished assembly, or decorative assembly from a third party. This approach can be a great production solution, especially if the actual operational delivery of your product isn't your company's forte. If you're working with a supplier in such a capacity, and the relationship has some history, you might be inclined to stay with your custom injection molder and just ride it out. However, if there are ongoing problems, finding a new source might be easier than you think.
If your work through the "break up" methodically, you can realize the cost savings and production improvements you desire without missing deliverables. There are several things to consider when making the decision to move injection molds from one supplier to another.
The ideal solution is one where the existing supplier, new supplier, and customer can openly communicate while maintaining all your deliverables. However, when this is impossible, having a supplier experienced with this type of transaction is invaluable. There is no substitute for experience and comprehensive planning.
The first step is establishing a sufficient inventory buffer before transferring the business. You want to avoid getting caught with too few parts on hand and causing an interruption in your business. At this stage, the current and new suppliers have specific responsibilities to ensure a smooth handoff.
Next, you'll want to clarify the deliverables regarding delivery, service, costs, and quality with your new supplier. It's a perfect opportunity to implement the improvements or enhancements you've been meaning to address—but didn't—because you didn't want to rock the boat. As the customer, you are also responsible for communicating known problems to your new supplier. If you want them to succeed, give them their best chance by communicating your goals and issues. Clear communication is critical at this point (indeed, throughout the entire process).
After everyone is on the same page, you'll want to ensure all parties are on board with cosmetic standards for the parts to avoid interpretation errors later. We recommend retaining each mold's last "acceptable" shot (part and runner attached if applicable) before transferring.
Finally, you and your new custom injection molder should develop an action plan to resolve any outstanding problems in accordance with future production needs and order of importance. Doing so will provide a successful foundation to build a lasting relationship.
To learn how to accomplish this process, download our guide, Mastering the Shift: 7 Key Points for Smooth Injection Molding Supplier Transitions. They say breaking up is hard to do, but with the right contract manufacturer as your partner, it doesn't need to be a heartbreaker.
Designing Injection Molded Parts
Injection Molded Checklist
Cut Costs on Injection Molded Parts
7 Aspects to Identify When Designing Injection Molded Plastic Parts
In Part 1, we discussed mold flow analysis (MFA) and the ways Ferriot uses it to improve the tool design process and, ultimately, the quality of the final custom injection molding we perform for our customers. In this segment, we’ll address questions about the Ferriot team's experience using MFA, the types of problems and pain points that have been discovered and resolved, and an example of savings that one customer experienced as a result.
Liz: Is this a pretty common process in injection molding with other companies? Or is it something that Ferriot feels is a strength that we bring to the customer?
Jerry: Although it’s a common process, there are a lot of companies doing injection molded part design that do not do mold flow analysis. Some people that build their own molds and are responsible for getting molds don't have this service. A lot of design shops don't have the experience to link part design with mold design and properly address how those two design processes marry together.
Not a lot of companies have this software and offer the link between evaluating things in the 3D world and the actual finished parts sitting on your desk. So, yes, this is one of Ferriot’s strengths, and it helps bring to life or show designers that aren't that familiar with plastics, the issues that they may have created unintentionally.
Liz: I can see where this provides both an experience edge as well as a consultive edge when you're working with our clients. I imagine that it’s especially helpful for designers that are not that familiar with injection molded parts. Is that correct?
Jerry: Right. For example, we get requests from startup companies or design houses that are industrial designers. They are looking for how a part is going to look or feel in their hands, but they haven’t taken into account how they're actually going to make it. By coupling our experience with MFA, that gives them a check and balance, per se, of their design. A saying I saw long time ago is so true: “For every vision, there's an equal and opposite revision.” We're trying to help prevent those revisions from happening after the mold is built.
Liz: I imagine that it gets costly.
Jerry: Yes. Once the mold is built, every change you make to it, you're looking at thousands of dollars. However, if we do an MFA with them before they started their mold, the little tweaks and changes are all but free. So, if you’re developing a new product and it includes injection molded parts, it pays to do your homework upfront. That's where our expertise in consulting and working through part designs with the customer prior to mold build, pays for itself and is a value-added benefit that we provide.
Ferriot engineers consulting with customer on possible mold design improvements
Liz: How long has Ferriot been offering the mold flow analysis and the tool design?
Jerry: In-house, we've been doing it about 18-months, going on two years. Up until then, when we were awarded a project, we would have our mold makers do it for us. Basically, every mold that we would build, would have this analysis done on it. Now, we’re doing this analysis in-house, and we’re doing it at the quoting phase, or to double-check everything at the quoting phase.
We've actually been providing the analysis for years, either by contracting the service or having a tool shop do it for us and working with them to get the analysis done. Later in 2019, we made a significant capital investment to bring in the tool internally so we can perform the analysis here at Ferriot on our own, saving time and money, while providing better control over it.
Liz: How many Ferriot people are trained to utilize the MFA software?
Jerry: We have three tool engineers that are trained to perform the mold flow, mold filling analysis. We also have process engineers who, although they're not trained to do it, they're very familiar with it and help to interpret results and review results and act as resources for the tool engineers as the analysis is being done.
Liz: What are the typical problems that you find when you do the MFA?
Jerry: It’s best to start with product design problems that we might unearth, and then move into tooling. One problem that I'm working on with a customer, we got the test part in, we quoted it, and we were awarded the job. We ran a filling analysis and with their material and due to the wall thickness, the part wouldn't fill. We tried multiple gating scenarios, to see if it would fill. It wouldn’t fill. I went back to the customer said, "Hey, this is the issue. We can't do anything about it without changing the wall thickness." Being proactive, we changed the wall thickness 20,000th of an inch and were able to fill the part. However, when we shared this solution with the customer, they said, "No, you can't change the wall thickness." The customer came back to us with three different resins. We ran the filling analysis and determined all three of them would work.
Example MFA simulation of nozzle boot flow fill time
But then they then came back to me later, "Well, we need to know if this is going to warp or not." We then ran a warpage analysis on all three resins, and now they're evaluating the warpage analysis to see which would be the best to use. So, thin wall thicknesses on parts or thin wall areas on parts could be bad, causing the material to somewhat hesitate as it flows through the part. Knowing that helps us advise the customer, "Hey, you have a part design problem here, you need to address it, and here are some ways to resolve it." The filling analysis gives us a lot of vital information of possible problem areas on parts, including issues related to wall thickness. If a rim or something is too thick, the analysis will show us a sink or a little dimple on the outside surface of the part. We can show that to the customer and say, "Because this wall is really thick, you're going to have a visual defect on the outside of that area." Sometimes it's okay, and they need the strength of that wall to be thicker, or "Oh, we didn't realize that was so thick, let’s thin that down and see if we can get rid of that visual defect."
Bottom line: There are numerous detailed reports within the results of the MFA, not only the answer to “will it fill properly?”, but it will identify areas that may not hold up under stress, where the hot spots or thick areas are in the mold. All of that data is available to review with our customers so they can alter their part design, if needed, to reduce or eliminate any problems.
Liz: Are there any interesting pain points that you guys were able to solve using this process? Are there any unique benefits that you've been able to offer customers because of having it, especially having it in-house?
Jerry: I immediately think of the value of being able to identify filling issues, even at the quote phase. If we are asked to quote a part, we can look at it and do it very fast analysis to identify filling issues that might stop the quote right there. We'd then let the customer know, "We can't quote this the way it's currently designed. We’ll have to talk about how to modify the design before we can provide a quote."
A lot of customers aren't even aware of these potential issues until we do our MFA. We've gotten quotes in from other people, and when we come back to them with this red flag, it kind of throws up a red flag of their own. Then they’ll ask, "Well, how did these other people quote it for us, and why didn't they bring up this issue?" So, it helps get into the nitty gritty of quotes and parts early with customers, which gives the customer a good, comfortable feeling about Ferriot, that Ferriot's providing them an extra service to help assure better parts. Hopefully, going that extra step helps us win their business.
Liz: How frequently do you find issues when you're dealing with mold transfers?
Jerry: I can speak for myself that I don't do a filling analysis on a mold transfer, unless we do have problems, but a lot of times there's not a whole lot we can do. That mold is built, it's been running production somewhere, and the customer is usually happy with the parts.
Now, if we have an issue with the part, you may be able to go back to the customer, run a filling analysis and say, "Hey, we're having this issue because of this issue." And I can show them the filling analysis of what's happening with the plastic as it's going around. Out of 50 transfer molds, that may happen once or twice.
Liz: So, the vast majority of mold flow analysis are done on parts in development, or molds in the tooling stage.
Jerry: Yes. It's a simple engineering tool that helps you make the best decision before that mold is built. The cost of the software quickly pays for itself. If you miss something that you have to make a mold design change after the mold is built, it pays itself a couple of times over just by preventing those future costs.
Liz: Can you give me an example, a success story of how MFA saved costs?
Jerry: A very large customer of ours came to us with a new product, which is highly visible. They were very concerned about strength. We ran multiple filling analysis for them to try and manipulate where some weld lines were going to be. Weld lines, whenever they are formed, they're weak areas of the part. We ran three or four analyses for them to get those weld lines moved: one, off a visual surface, and two, off of structural areas. If we wouldn't have done that, this mold cost us in excess of $200,000, we probably would have been redoing half of it. So, that was an exceptional savings in both time and money.
Liz: That’s a great example! For those of us who don’t know, please explain what a weld line is?
Jerry: To make a hole on a plastic part, there has to be steel in that area of the mold. Imagine the plastic is flowing like a river. The piece of steel that's in the mold to create the hole, think of that as a rock in the middle of the river. Now the water hits that rock, it has to flow around it, where the water comes together on the downstream side of the rock, or come together and welds itself back together, that’s what a weld line would be. It will fill in, but it's not as strong. That's a weld line. If you look at it closely, a tiny little line in the surface of the part. Eventually, as you get further away from the hole or further downstream, then the plastic starts flowing consistently again. But where it comes around that hole or the rock, it slams itself together.
By adjusting gate location, cooling, and other parameters, we can move the weld lines around in the part. When using the mold filling analysis, we can project where they are going to occur. The weld line is a slight visual imperfection, and it has a reduced strength. It's important to the customer where that weld line is going to fall in part. By using MFA, we can predict where it's going to occur and move it, if we don't have to, by making adjustments to the tool design.
Liz: How would you summarize the mold flow analysis (MFA) process advantage?
Jerry: Simply stated, it’s an engineering tool that helps Ferriot and its customers make an informed and educated decision before moving forward with the development and creation of the actual mold, saving both time and money, while resulting in a stronger, higher quality end product.
If you have a question about mold flow analysis and how Ferriot can use it to help you with your next injection molded part tool design, feel free to contact us for a FREE initial consultation.
[post_title] => How do Mold Flow Analysis and Tool Design impact injection molded part quality? [Part 2] [post_excerpt] => Ferriot offers in-house mold flow analysis (MFA) as part of our custom injection molding design process | See the real-world impact of design on molding [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => how-do-mold-flow-analysis-and-tool-design-impact-injection-molded-part-quality-part-2 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:09 [post_modified_gmt] => 2024-03-11 20:11:09 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-how-do-mold-flow-analysis-and-tool-design-impact-injection-molded-part-quality-part-2/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [23] => WP_Post Object ( [ID] => 2268 [post_author] => 3 [post_date] => 2022-03-24 13:55:00 [post_date_gmt] => 2022-03-24 18:55:00 [post_content] =>
To properly benefit from the advantages of using structural foam parts in your product’s design, first, you need to understand the process.
Here’s how it works. The structural foam injection molding process uses a foaming agent (typically nitrogen gas or chemical blowing agent) added to a resin polymer as it melts, then injected into the standard injection molding tool (or die). In this process, the blowing agent activates and pushes resin uniformly into the cavity pockets; as the part cools, a solid skin forms against the mold. Inside the mold, the resulting foaming action produces a honeycomb-like structure behind the solid skin while reducing post-mold shrinking.
The resulting structural foam part is significantly lighter than other parts produced using other standard injection molding processes. The majority of structural foam parts utilize this injection molding method to reduce the overall weight of the part by up to 30%. However, lower weight isn’t the only advantage. Structural foam molding can provide several benefits you may want to consider as you plan your next project.
The key to using structural foam parts successfully is in the ability to incorporate them into today’s complex custom mold designs. To learn more, download our whitepaper, Structural Foam Injection Molding Resources Guide.
To learn more, download the Structural Foam Injection Molding Resources Guide
Mold flow analysis (MFA) and tool design are both very important aspects in the injection molding part design and troubleshooting process. They help assure that a new mold tool design will yield quality parts that meet or exceed expectations.
Jerry Graf is the Manager of Engineering and he’s in his third year at Ferriot. He has about 36 years of industry experience, a lot of it in the automotive industry. Over 10 years of this experience is focused on the injection molding side of things.
In this discussion, I had the opportunity to learn a lot about MDA and tool design by talking with Jerry on his experience and expertise.
Liz: Could you explain a little bit about mold flow analysis and why Ferriot uses it?
Jerry: When I begin a new part design review, I use it mainly to determine the best place to gate the part. That, coupled with talking with the customer on visual requirements. I want to make sure I'm not gating on an appearance surface. That's kind of the first step is determining where I can gate it. Then, I would go in and model a 3D part file using a gate location and size that I think would fill the part based on the wall thickness of the part and on the material that they specify. Finally, I'd run a filling analysis to see if the part would fill.
If that is successful, then the next step would be to do a warpage analysis to see if there's any internal stresses created by that gate location that was chosen and see if the part will work. If it will work, will it be acceptable to the customer in the final assembly of the part? Another thing that the filling analysis will do is give me an idea of where some visual defects may occur, such as weld lines and flow lines, which usually occurs or always occurs around openings in the parts or holes in the part. Sometimes we want to keep those weld lines off appearance surfaces. For example, if a gate would need to be moved to push that weld line in the location where it would be inaccessible for the customer to see.
Liz: You referenced the term gate a couple of times. That is where the materials come into the mold, correct?
Jerry: Yes. The plastic goes into what we call a runner, from a machine into a hot runner, then to a cold runner. Then the cold runner enters the gate. Think of the gate as where you open up into the part. So, the gate is where plastic first enters the part.
Liz: So, what would happen if a gate was incorrectly located?
Jerry: Well, once I do the filling analysis, if I share that with the customer and have them tell me "Yes, that's okay," or if it's visually acceptable, and then we will review the warpage analysis, and if the part is able to be filled. If it wouldn't fill, or if it was creating a visual defect that was unacceptable to the customer, then we would just pick a different gate location based off of their feedback of the visual requirements. We can run multiple analysis’ with multiple gate locations, just to emulate all that happens in the tool before we build the mold.
Liz: Is there any other critical information that the mold flow analysis would provide?
Jerry: It also lets us estimate cycle time, that is, how long it will take to fill the part, cool the part, and get it down to a temperature where it can be ejected from the mold. Knowing the cycle time information helps us better estimate the piece price. It provides a more accurate representation of what our costs would be and what the piece price would be.
If we get a warpage condition that is bad, we may determine to hold it in the mold for a little bit longer, which the software can simulate. And then, we're going to see if we can get our warpage to an acceptable level, which helps us again, determine cycle time or how many parts we can produce in an hour, which influences piece price.
Ferriot engineer reviews MFA software simulation looking for opportunities to make improvements
Liz: All of that obviously influences not only the speed at which we can produce the parts, but also the quality of the parts, correct?
Jerry: Yes. If we go too fast, we could potentially have a quality issue. We use the MFA to make sure that the gates are in the proper locations, the material coming into the mold is going to do so smoothly, in the most timely, cost-effective manner and produce the best quality part for the customer.
To take it a step further, in every mold there are water lines flowing through it. The water helps the steel (of the mold) remain at a constant temperature. If we have some geometry that we're concerned about in the part’s design that's taking a really long time to cool, we can model-in water lines to cool that area of the mold better, to optimize the cooling of that part. We can model not only the plastic through the part, but we can also model the water lines going through the steel of the mold.
Liz: The objective is to make sure the whole part is cooling in a similar timeframe, and you don't have parts that are hotter and cooling over a longer period of time.
Jerry: Right. If you have an area in the part that takes longer to cool and another area that cools much faster and will be solidified, if you eject it too fast, there could be a lot of opportunity for warping once you eject it. You want the whole part to cool down all at the same rate. Now, we can manipulate the steel or even manipulate the mold steel by using copper, which draws the heat out faster. If we force water into that copper, it pulls the heat out even faster.
Running the filling analysis gives us insight into problem areas in the parts, areas that we should pay attention to in the tool design, and that give us a good representation of what would happen inside that tool before we actually start cutting steel, which is where it gets really expensive. If you start making changes after you’ve started building the mold tool, you could be scrapping pieces of steel as well as man-hours, which is expensive. So, it's not only beneficial from an engineering side, but it's also more cost-efficient to do the MFA before you start building the tool.
Liz: The value of MFA on the tool design process and the overall troubleshooting process is certainly becoming much clearer. Using MFA early in the design and development of the part makes sense. As long as the customer has a pretty good feel for the shape and size of the part, using MFA really helps move forward with the tool design in the most cost-effective manner.
Jerry: Yes. We'll step back a little bit further in the tool building process. Sometimes, I use MFA when I get a request to quote and we haven't been awarded the job yet. So, I'll use that to help give us a better idea of: Will the part fill? Is their design bad and we just can't fill it? Then, maybe at the RFQ, we'll go back to them at their time of quote and say, "Hey, we've quoted this way, but we see this issue or two that need to be addressed first."
Now, we typically only do that for customers with whom we've had a longstanding relationship. We don't always want to give our engineering work away for free, but if we have a good working relationship with a customer, then we're more receptive to do that at no cost to them. Now, if we are awarded the job, then yes, we immediately start into: Is the part moldable? Where are we going to gate it? Are we sure it's going to gate okay? Some of these items are very simple that we know it's going to fill just from experience in the wall thickness and the material or the plastic. However, there are times when there’s a red flag, "Hey, I better run an analysis on this just to make sure we can fill it."
To be clear, the mold flow analysis is not only helping guide the tool design, but it also can help guide the part and product design.
Liz: What if a customer doesn’t know what resin material to use in their part?
Jerry: Some customers do come to us with a part design, and they know the requirements of the part and they have narrowed it down to a classification of material. Based on that, and some of the physical requirements in its final assembly, we can make recommendations on some material to use, and run the filling analysis using different materials. This helps us guide the customer in selecting, not only the most cost-efficient resin, but one that would fulfill the physical requirements of the part after it's molded. Instead of building a mold and just trying a bunch of different plastics with it, if they're not 100% confident on the resin that they want to use, but have their specific requirements defined, we can take those requirements of the plastic and help them narrow down the selection.
Liz: So, it's entirely possible that a customer could come to you and say, "This is the resin I want to use for my part," and after you've completed the MFA, you guys might say, "Well, if you move from this resin to this resin, you'll end up with a part that's stronger and more durable for a little more cost."
Jerry: Yes. Or, if resin A is okay, but resin B is less expensive and still performs the same, we can also prove to them that, "Hey, we can get a little bit of cost reduction if your design will allow it." There are other considerations, things that could impact that, such as UL approval, other agency approvals, that kind of stuff. We must be careful with these recommendations, as some resins are approved and some are not.
Use of MFA can help avoid problems before completing a mold and taking the part to press
In part 2, we’ll answer the questions:
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The past few years have certainly had their challenges. The COVID-19 pandemic contributed to supply chain disruptions and limiting manufacturing capabilities to quickly get products molded, assembled, and to the market. That, coupled with the resin crisis resulting in higher prices and longer lead times, has made it more critical than ever to make smart injection molding resin selections.
At Ferriot, we've felt our client's angst. Everyone needs to adapt and adjust to meet their company's objectives. In some cases, that has meant evaluating the current resin selection and changing to another resin to keep production schedules on time and meet delivery dates without compromising quality and reliability.
The challenge is determining what resin is the right resin—the best resin—for the product. It’s essential to take some time to learn about the characteristics of thermoplastic resins. There are many different types and grades available, or in some cases, in short supply and hard to get delivered on time. These thermoplastic resins fall into two basic classes: engineering grade resins (nylon, polycarbonate, ABS, PC/ABS, TPE, acrylic, acetol, and structural foam) and commodity resins (polypropylene, polyethylene, polystyrene, and PVC). Each category includes various resins that provide the flexibility to match a resin to a part based upon application, part design, and moldability.
When considering all the product design requirements and the challenges of manufacturing a product in a post-pandemic world where the supply chain isn’t back to what it once was, resin selection can be a daunting task.
Over the years, we've provided several valuable guides to assist with resin selection, including The Tips, Tricks, and Traps of Injection Molding Resin Selection and the Injection Molding Resin Selection Workbook.
We've added the webinar, How to Make Smart Injection Molding Resin Selections, this year. This informative webinar addresses several important considerations when specifying resins for your next project. Learn the answers to these critical questions:
We think you’ll find the time you take viewing this webinar time well spent. If you have further questions, don’t hesitate to ask.
Learn more:
New press further increases customer service speed and production capacity
To help meet the increasing demand of custom injection molded parts in markets from electronics, to industrial and medical industries, Ferriot recently installed another press! Smaller than the Negri Bossi BI-POWER installed by Ferriot in 2018, the newest press in Ferriot’s line is the Negri Bossi s850T-7460 series molding machine.
As part of Ferriot’s equipment upgrades and plant reorganization, this new 936-ton press was installed in Q3 of 2020. The new acquisition adds capacity with the current 720-ton press still in operation. The new press fills a gap between the 770 ton and 1500-ton presses. Updates in technology allow this press to use less energy but provide more tonnage pressure and tighter tolerances.
“The new Negri Bossi press further increases our operational efficiency and production capacity. Adding this new press helps us to further instill confidence in our customers that we will always have the custom injection molding capabilities to quickly turn around their orders,” says Craig Ferriot, company president.
The Negri Bossi NOVA s850T-7460 incorporates the following features:
Negri Bossi Motus Multi-Touch Controller
Negri Bossi s850T-7460 series molding machine fills the gap between existing 770 ton and 1500-ton presses.
Ferriot’s current injection molding parts production fleet includes the following:
| # of Presses | 20 |
| Clamping Force (tons) | 56 - 2250 |
| Barrel Capacity (oz.) | 2.7 - 344 |
| Maximum Mold Weight (tons) | 20 |
| Minimum Mold Height (in.) | 5.9 |
| Maximum Mold Size (in.) | 60.9 x 89 |
Interested in hearing more about how we’re growing to service all your custom injection molding needs? Would you like to be notified when new blogs are posted? Subscribe to our blog so you never miss an update. If you have a question, don’t hesitate to ask!
Newly molded gas pump parts exiting the latest Ferriot press, a Negri Bossi NOVA s850T-7460.
Learn more:
Energy
The Russia/Ukraine conflict is rapidly evolving, and its global impact on oil and gas has yet to be determined. Consumers are currently seeing gas prices rise during this volatility. Inflated pricing will impact transportation and logistics, and the increased costs involved with moving materials will at least keep resin pricing up for the time being.
Logistics
High demand for goods continues to stress supply chain logistics for imported resins and resin feedstock. As of mid-February, we have ten orders to ship for every available truck on the road. Bulk trucking is having difficulty keeping up and experienced unexpected dropped loads recently in the Southeast US and Midwest due to winter storms.
Constraints on moving goods mean warehouse storage near our busiest ports is beyond maximum capacity, and they cannot accept additional containers until the containers that are waiting on the docks ship. Railcar storage is also beyond capacity due to the need for cars to be emptied and released. Collectively, this impacts port congestion, with all ports and sites near the ports being over 100% of the agreed-upon capacity.
Resin
Though resin producers have recovered from weather-generated shutdowns and planned plant turnarounds, demand remains strong, and prices continue to settle or increase slightly. Supply issues remain, so expect to see continued force majeures and sales allocation through 2022. Some inventories are beginning to grow, but additive shortages continue to impact availability. Overall, prices have bottomed out, but price increases will continue due to logistics and staffing issues and energy cost increases.
| Type | Pricing | Supply | Detail |
|---|---|---|---|
| Polyethylene (PE) |
Increasing Pricing is still up 26 cents per pound since January 2021, even after a 15 cent decrease from Q4, 2021. |
Sales have picked up with improved demand. Some limitations are expected due to planned and unplanned outages and co monomer supply issues. Transportation issues continue to plague export market. |
HDPE – supply available with forecast LLDPE Branded is available with forecast LDPE – tubular products fully available. Autoclave remains under supplier sales control. |
| Polypropylene (PP) | Steady to increasing. Pricing is still up 24.5 cents per pound since January 2021, even after 40 cent per pound drop between Sept – Jan. | Domestic supply is available. Imports have arrived, but are short-lived. December production below 70% was unexpected due to strong margins and lack of weather events. January is also light production month. | Rail car availability is a constraint to production levels. Spot pricing is moving up. Imports slowing. |
| Polystyrene (PS) | Steady to increasing. | Lack of import availability | |
| ABS | Volatile and increasing | Imported ABS keeping domestic pricing up. Ocean freight increasing exponentially, sometimes doubling in one month. Ports overloaded with peak season surcharges being assessed to Ocean Freight. |
Strong demand, continued raw material shortage and unprecedented logistics issues continue for imported ABS. |
| PVC | Slightly up but flattening. | Most suppliers have lifted Force Majeure, but maintain order limitations. | There are still sourcing constraints on additives and plasticizers limiting some availability, driving prices up and extending lead times. |
| TPE | Steady | Materials available | |
| Polycarbonate (PC) |
Firm Pricing will remain firm for first half of the year. |
Several Covestro suppliers are still on Force Majeure or sales allocation. Additives (especially FR): ABS and Polyester are very challenging. |
Makrolon and Bayblend remain on sales allocation with 11-13 week lead times. Makroblend (polycarbonate / Polyester) remains on Force Majeure with a 13 week lead time. Polycarbonate is not the issue. |
Difficulties in supply chain logistics continue to add to resin lead times. This is especially true now that the Christmas season is upon us with consumer goods competing with raw materials on cargo space. Imported material is impacted by container availability and congestion at the ports. Even once containers arrive and are offloaded, trucking availability and persistent congestion at rail terminals add to lead time. Resins produced in North America can also have delays due to limited availability of trucking and driver shortages.
| Type | Capacity | Comments |
|---|---|---|
| Bulk Trucking | VERY limited – demand is exceeding supply. | Supply/demand imbalances seen in the Southeast US and parts of mid-west (Kansas City & Ohio). |
| Dry Van: Full, partial & LTL | Limited – demand exceeds supply, reducing service levels and increasing cost. | Truckload market under-capacitized and carriers moving to LTL network. |
| Shipping ports | Port congestion continues to be EXTREMELY problematic delaying delivery of imported containers and increasing costs. | Downstream bottlenecks contributing to slow movement of containers. Some are being routed to other US ports. |
Though resin producers have recovered from weather generated shut downs and planned plant turn-arounds, demand continues to be strong and prices continue to be settling or slightly increasing. Supply issues remain, so expect to see continued force majeures and allocation into next year. Some inventories are beginning to grow, but additive shortages continue to impact availability.
| Type | Pricing | Supply | Detail |
|---|---|---|---|
| Polyethylene (PE) | Prices settling and remaining flat. | Supply continues to improve with only a few issues with some additives. Still strong domestic demand, but inventories now climbing due to reduced exports and plants running after shutdowns and turnarounds. | HDPE – improved LLDPE C4 available, C6 & C8 grades remain snug LDPE – some branded material remains under sales control. |
| Polypropylene (PP) | Prices settling. | Imports hitting US market at double 2020 average. Plant operating rates improved and inventory building partially due to September sales decline. | Potential limitations on key materials: Peroxide shortage impacts high melt products. Additives for resin stabilizers imported from China seeing delivery delays. |
| ABS | Volatile and increasing | Ocean freight increasing exponentially, sometimes doubling in one month. Ports overloaded with peak season surcharges being assessed to Ocean Freight. | Strong demand, continued raw material shortage and unprecedented logistics issues continue for this import. |
| PVC | Slightly up but flattening. | Most suppliers have lifted Force Majeure, but maintain order limitations. | There are still sourcing constraints on additives and plasticizers limiting some availability, driving prices up and extending lead times. |
| TPE | Steady | Materials available | |
| Polycarbonate (PC) | Pricing up | Several Covestro suppliers are still on Force Majeure or sales allocation. Additives (especially FR): ABS and Polyester are very challenging. |
Makrolon and Bayblend remain on sales allocation with 11-13 week lead times. Makroblend (polycarbonate / Polyester) remains on Force Majeure with a 13 week lead time. Polycarbonate is not the issue. |
| Acetal | Expect price increases to continue. | The market is short due to strong demand, import shipping issues and force majeures. Lead times extended on imports. Texas plants still on Force Majeure due to weather related issues. | Shipping costs are sharply rising and Methanol prices are higher. |
| Nylon | Further increases expected | All supply is very tight. Production is improving but backlog of demand will keep producers including BASF on Force Majeure. | Nylon 66 pressured for further increases due to raw material cost. Nylon 6 compounds are up as well. |
Last month, in our article “How to Get Your Injection Molded Parts On-Time and Keep Your Production Lines Running,” we addressed the lead times and production concerns around the resin industries and what Ferriot is doing to help our customers weather the storm. We will continue to update you on this evolving issue.
Plastics processors all over the country are seeing severe resin shortages and staggering price increases. Every indication is that this issue will continue through June. What caused this? What resins have been impacted? How will this impact the resin market in the coming months? What should OEMs with plastic components in their products be doing now?
What Happened?
The root cause of this crisis is the COVID-19 pandemic (see diagram). 2020 and the beginning of 2021 have been a battle, especially for Texas and Louisiana resin manufacturers. Like many, resin manufacturers experienced some shift in product due to COVID-19 disruptions. To abide by COVID-19 rules and regulations, many plants ran into staffing issues as production facilities, shipping ports and supply chain logistics all saw a slow down when quarantined production shifts removed days of labor, as well as short staffing because of symptomatic employees. As a result, many thermoplastic resins were already in tight supply. Then, in the middle of the COVID-19 pandemic, the south saw one of the worst hurricane seasons in years causing increased delay, as well as damage. In February, the United States was hit with Winter Storm Uri resulting in power outages across the country.
Timeline of issues impacting resin supply (Source: MAPP and AMCO Polymers)
Current Market Status
Now, several weeks later, the Louisiana and Texas plants are still recovering from the national winter/ice storm that caused so many shut-downs. Subsequently, there is more demand than supply for thermoplastics. According to Plastics Today, as of last week, at least 80% of domestic resin producers are in force majeure. Polyethylene, Acrylonitrile Butadiene Styrene (ABS), Polyvinyl Chloride (PVC), Acetal, Polycarbonate and Nylon being several major polymers that have been affected by this crisis.
Price increase announcements in Feb/Mar 2021 (Source: MAP and AMCO Polymers) Products in RED have supply on Force Majeure.
What does this mean for us?
Why does that matter to you and the production of your injection molded parts? Well, Polyethylene is the most widely used plastic in the world, 85% of U.S supply being created in Texas. Without Texas plants able to produce and ship these essential plastics, we are going to start seeing significant plastic shortages, and potentially empty shelves at the store, in healthcare, automotive, construction, etc. Remember how the toilet paper shortage of 2020 resulted from the COVID-19 shutdown? It resulted in increased high demand. Many plastics consumers are going to buy out supplies as we continue to see a decrease in product. What does this mean? Higher prices, ongoing allocations, longer lead times, etc. According to Plastics Today, Polyproplene resin prices alone rose an average of 34 cents per pound in February and are expected to continue going up through March as a result of the strong global demand and short supply.
But since the storm is over, we should be moving forward, right? Not exactly. As recent as last week, Texas was still working to restore power to those who still don’t have it. However, once power is fully restored, plants must then evaluate the effects that this storm had – product allocation, order status, lead times, transportation, etc. Most plants that were affected by freeze related shutdowns did not anticipate the shutdown having this high of an impact. As a result, most plants were unable to properly prepare production and machinery for what resulted in the shutdown.
What should we do?
As we continue through the resin crisis, Ferriot recommends working with your current supplier to confirm allocations, as well as future supply. The resin crisis will continue to get worse before it gets better. We are anticipating this crisis lasting through June, if not longer. Our engineering services team can work with you and your suppliers to help identify alternative resins that you can use while we navigate these strange times. Learn about the pros and cons of each different resin and see if an approach to pivot your resin selection in the short team is something that your business should consider. Then, be ready to give long-term commitments for supply today, knowing that this crisis is set to continue for months to come, and low-priced resins will likely experience a pricing increase as this resin shortage continues to be a battle we face.
How are we going to avoid this in the future?
As we work to get past this crisis, an important thing to remember moving forward is to have a committed branded distributor. Talking with your distributor about your forecast for the year and volume requirements will not only help them plan and prepare for your demand, but it will also keep your company top of mind if a crisis does occur. Right now, in the resin crisis, companies are submitting orders to manufacturers and are getting terms such as “30-week lead times” thrown at them. When you have a committed relationship and requirement already in place with a manufacturer, your forecasted supply is already being factored in, resulting in quicker product response times. Having a committed relationship will also allow you to have some “buffer stock,” on hand when these types of delays occur again. Lastly, remember, resin crisis or not, the more lead time that you can provide your supplier, the less you will have to worry about hiccups delaying your products again!
Conclusion
As resin plants continue to regain power and recover from the latest setback, companies continue experiencing productivity issues due to labor challenges of COVID-19 and supply of both domestic and imported resins continues to fall short and worsen, the resin crisis remains an issue across the country. Consult Ferriot’s engineering services team and your branded distributor immediately to develop a plan on how your company can combat this setback. As a reminder, the best way to address the current resin crisis is to be proactive by taking these steps now:
Resin Pricing Update: May 12, 2021
The resin market continues to face ongoing delays and shortages as a result of the Covid-19 pandemic, a record hurricane season, and winter storm, Uri. Many resin lead times are extremely long. The team at Ferriot continues to monitor the price fluctuation of our country’s most popular polymers.
- PGP settled down $.13/Lb. for April to $.57/Lb. Throughout the month of May, we are predicting that the pricing is going to decrease.
- Given the supply/demand imbalance, the market tightness remains for Branded Polypropylene. As of April 30th, seven out of 10 N.A. PP producers remain on Force Majeure.
- Pricing for Polystyrene continues to increase, and we predict continued price increased throughout May.
- ABS pricing continues to rise as well with a $0.61/Lb. price increase on general-purpose ABS since September 2020 and $0.32/Lb. on enhanced specialties.
- With three of the four major North American PVC resin production facilities still operating under Force Majeure, multiple PVC resin producers announced a $0.07/Lb. increase for March, with two producers announcing an additional $0.07/Lb. for April, with likely another on the way in May.
- PC is another that has seen shortages due to the series of many events that have put many manufacturers into Force Majeure.
- As for Nylon, all supply continues to be tight as production works to build back up.
Popular brands of blended resins still have long lead times as well:
-SABIC PC/ABS blends, Cycoloy and Cycolac still have a 19 week lead time.
-Covestro’s Makrolon (PC) and Bayblend (PC/ABS) still have a 13 week lead time.
In addition to the increase in individual resins, companies and locations across the world are still seeing the impact.
- Since September of 2020, a total of $0.62/Lb. of price increases have been announced by ChiMei. Lead times at ChiMei continue to stretch 12-14 weeks as the manufacturer sells out of all resins
- The cost of Taiwan to Chicago increased to $1,500
- While we continue navigating these shortages, excessive port delays and intermodal freight could add 3-5 weeks for delivery for any resin
Demand is expected to continue to be strong through the summer months with raw material costs increasing. As companies work to bounce back, they are also tasked with the ongoing battle of long lead times that keep them under Force Majeure. Throughout these months, it is important that we are planning ahead when we can, as well as substituting preferred resins for alternatives when available.
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When reviewing projects with your injection molder, remember to discuss what value-added or secondary services they provide beyond molding your parts. Consider selecting one company that can handle all of your custom injection molding, painting and decorating needs. Using an injection molder with comprehensive services that include painting and decoration capabilities saves time and lowers your cost.
Two-color pad printing machine
When you work with an injection molding company that also does the painting and the decorating, your production lead time is minimized because no additional transit time is added to ship parts from the injection molder to the company providing the finishing services. This also means that there is no additional freight cost added to the final cost of the finished product.
Working with a company that does both processes in-house also means more time can be saved because full-service injection molders can optimize the production, painting, and decorating of your products efficiently and in a cost-effective manner. Manufacturing cells are flexible and customized for the products being made. A good example of this would be an enclosure with specific color requirements and a company logo. An injection molder with painting capability can look at the options of color matching the resin versus painting the parts once molded. This optimizes your products, and gives you options where cost, appearance and performance can be considered before making the final decision. Once you determine the process for achieving part color, the method to be used for application of the logo can be considered.
The most common choice for incorporating brand names, logos, instructions, and other markings on plastic products is pad printing. Many customers are drawn to pad printing because it provides the capability to place a 2D image onto a 3D surface. The process of pad printing utilizes a silicone pad, and its flexibility allows it to easily adapt to irregular surfaces that could have various textures or recessed areas.
In this example, pad printing is used for both two-color branding
and to provide warning instructions in black (top of part).
What are the advantages of pad printing?
When it comes to adding your brand or other information to your injection molded parts, pad printing offers some very valuable advantages:
Pad printing is particularly useful when the surface on which the logo and product name is must appear on an irregular surface. In this case, the imprint area is curved rather than flat.
Is pad printing right for my product?
The pad printing process is commonly used on products in many industries and numerous applications including:
There are 2-color and 4-color options that provide durable results whether you’re printing company logos, product names, user instructions, and operational indicators.
What details are needed for your pad printing job?
To ensure the successful pad printing of your injection molded parts, you will need to provide specifications, graphics, and set up instructions. The list below is a great guide to help you prepare for your pad printing job:
Visual instruction icons being pad printed
where controls will appear on the final product.
Are there additional pad printing costs?
Other than the ink needed, there are some one-time setup costs that could run between $1,000 and $1,500. Additional costs that you can expect when getting started with your pad printing project include:
| Holding Fixture to hold the part in place when printing | $550 |
| Artwork | $190 |
| Cliché image plate | $280 |
| Ink Color Match | $140 |
| Silicone Pad Print Pad | $75 |
One of the most common reasons our customers turn to pad printing is its cost-effectiveness. If you have high volume parts, need a limited number of colors and/or very small areas to print while maintaining high quality and tolerances, pad printing is a great choice.
Before any pad printing job, make sure that you review the project with your injection molder to discuss your unique requirements. They will know the questions to ask, and will understand how your application, shape, size, material and surface finish will impact your desired results allowing them to provide you with a quality product.
If you need further assistance, don’t hesitate to ask us your questions. We’re here to help!
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You’ve probably heard that a picture’s worth a thousand words. However, according to George Popov, quality supervisor at Ferriot, a picture’s actually worth a million numbers — at least in the world of custom injection molding part inspection.
Armed with just one piece of inspection equipment (a CMM), Popov was seeing his department become a bottleneck in the inspection process. So Popov and his team selected a new piece of equipment — an Aicon SmartScan scanner with third-party PolyWorks software.
Among the factors that influenced their decision was the scanner’s ability to present inspection data in a colorful, easy-to-grasp format. The PolyWorks software allows users to introduce a color map to the scanned image, showing where and by how much the part being inspected deviates from the CAD model of an ideal part.
The visualization of inspection data is key to connecting with customers. If a customer is struggling with a faulty part, the color maps and virtual inspection tools help illustrate the exact problem at hand. And it can confirm the accuracy of the inspection process and protocols being utilized.
But that doesn’t mean you should get rid of your CMM. In fact, Popov explained that the scanner and CMM work together to provide a more comprehensive inspection process. In addition to visualization, the inspection tools have helped Popov’s metrology lab increase throughput and enhance flexibility.
To learn more details from Popov’s interview with Plastics Machinery Magazine read the full article here.
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Cobots Enable More Efficient Manufacturing in Injection Molding
What is Gas Assist Injection Molding?
The reason for injection molding delays is that resins – the materials that your plastic parts are made from – are in short supply. With lead times for resins increasing and their cost going up, it’s only natural that your injection molded parts will face the same challenges.
Increased lead times and prices are significant obstacles for any industry. The problem is that these challenges may not be going anywhere anytime soon. The COVID-19 pandemic has caused a delay in resin production while simultaneously causing demand to skyrocket. Not only are plants slowing down during the pandemic, but many US companies are also reshoring production. Couple that with winter maintenance shutdowns and outages – both planned and unplanned – and you have the perfect storm for a volatile market.
Now, everyone is scrambling to get their resins quickly, and many companies are being left behind in the process. That means that, in the fast-paced world of modern industry, manufacturers relying on quality resins are going to face:
That’s why the resin experts at Ferriot are here to help you plan for success by meeting these challenges head-on so that you can keep your production lines running.
How is Lead Time Being Affected?
When everything is running smoothly, resin lead times are often rather reasonable. After sending in a purchase order, you could expect a resin in only a few weeks, a month at most. Quick resin lead times mean that you get your parts faster, and your business can continue running smoothly.
Current lead times may not look so bad at first. Quoting a lead time of about 4-5 weeks is pretty standard in the current financial climate… but those lead times are misleading. As the COVID-19 pandemic causes waves in the chain of supply and demand, that 4-week lead time can turn into 8 weeks a day later, and then 12 weeks the next. Before long, those initial 4 weeks will have passed with no end in sight.
Without the resin, you can’t make the injection molded parts that you need. The impact of the current pandemic has done a real number on manufacturers, causing many of them to put a halt on projects and hold off on any decision making until things settle down.
What Resins are Being Hit the Hardest?
When it comes to resin selection, there are two main categories of resins: commodity resins and engineered resins. Depending on which type of resin you need, you’ll face a slightly different market with its own issues.
If you’re working with commodity resins, you are most likely working with one of the following three choices:
These commodity resins have been facing increasing challenges with lead times and prices since the start of the COVID-19 pandemic. Since these more general resins are so closely tied with many different applications and products, they are the resins that are affected the most by the supply/demand cycle. Currently, polyethylene and polypropylene resins are even harder to get than polystyrene resins.
Engineered resins, also referred to as custom resins, are resins that are tailored to a specific application or product. Since these resins often lack the mass production of typical commodity resins, it has only been in the last couple of months that we’ve really seen a significant spike in lead times and prices.
What makes the selection process especially difficult for engineered resins is that you usually pay when the resin ships, not at the time of the purchase order like you typically do with commodity resins. This means that the price can go up as lead times are drawn out. Now, not only are you waiting a few months instead of a few weeks for your resin, but you’re also paying more for it than you expected.
No matter how or why a resin costs more or takes longer to get, all of these things will directly affect the lead times and prices of their resulting plastic parts.
How Do I Get My Production Up-And-Running Faster?
If you want to overcome the current challenges of the resin market, then you’ll want to partner with a resin selection expert like Ferriot.
In order to keep our customers competitive, we’re implementing a number of key initiatives to help mitigate the effects of the current pandemic on your production lines. The goal is to mitigate downtime and allow you to push forward even in these challenging times.
Controlling the Controllable
We can’t control what other companies do or how the market shifts. However, there is some work that we can do upfront to help you get your resins as quickly and as cost-effectively as can be.
By partnering with the injection molding experts at Ferriot early on, we can help streamline your time to market. We can also help to manage resin lead times through our supply agreements and by ordering as soon as you select a resin.
Planning for Unpredictability
If you want to plan for success in a changing market, you need to remain agile. That means having a backup plan.
As you are planning out your design, the resin experts at Ferriot can work with you to come up with a backup resin (or two!) that can still fulfill your design needs. Specifying more than one resin on your prints is the most important thing that you can do if you want to ensure that you get your injection molded parts as fast as possible.
By selecting multiple resins, if your first resin choice is too costly or has an exorbitantly long lead time, you can still get a usable resin within your desired time frame. That flexibility also helps to manage any risk of a resin being discontinued or being single sourced.
Specifying multiple potential resins gives you the flexibility to continue production on existing products, as well launch any new designs. Ferriot can also help you to negotiate better resin prices while safeguarding against rising costs by locking down prices earlier.
To learn more about getting the right resin for the job, take a look at Ferriot’s Injection Molding Resin Selection Workbook for more information.
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When it comes to new technology, what makes it a success? The platform? The interface? The added features? No, in fact, it’s all about the talented people involved with implementation.
At Ferriot, we know what it takes to decrease failure rates and guarantee success with the new technologies that we implement to better serve our customer’s custom injection molding needs. And we know how the success of any new technology relates to the people implementing and using it to do their jobs better. The way the people in your organization work together to handle both simple and complex problems contributes to your organization’s culture.
To make new technology a success, your culture should manifest the following skills and strategies:
Before you start planning a new technology implementation, take inventory of your team’s interactions — especially when facing challenges. Is there a strong sense of trust? Is there a shared feeling of comradery? If so, your team is much more likely to experience a successful outcome.
We recently talked about this subject with Industry Week. To learn more, read the full article here.
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The year 2020 has been a tough one, especially for manufacturing. Due largely to the COVID-19 pandemic, the manufacturing industry saw a decline of nearly 23 percent in 2020. The simultaneous shock and demand from shutdowns, the financial crisis, and increased workplace regulations have created the perfect storm for what’s likely to be the worst hit to manufacturing we’ve seen in decades.
However, in light of recent times, businesses are still finding ways to rise above and prevail. Through advanced processes and increased technology adoption, manufacturing companies can, and will, survive the storm.
Now more than ever, it’s important to recognize good manufacturing and the smart businesses that are leading the charge for long-term, sustainable growth. That’s why Ferriot is honored to be among the 35 companies receiving a 2020 Business Growth Award from Cascade Capital Corporation.
Recognizing Success
To help reinforce the positive during these times of uncertainty, Cascade Capital Corporation has recognized 35 Northeastern Ohio companies at their 2020 Business Growth Awards Program. These awards showcase a company’s continued success and growth, highlighting their crucial role in supporting and revitalizing the local/regional economy.
Companies can earn a Business Growth Award by either increasing sales by 100 percent/$5 million or by increasing its employee base by 50 percent/25 people during the past five years of business. The profits, goods, and services generated by these companies help to invest in the economy while opening new facilities and hiring additional employees.
On October 1st, Cascade Capital Corporation presented Ferriot and the other honorees with their award during a live virtual event. Companies that received an award will also be featured in a special editorial report in the October edition of Smart Business Cleveland.
Ferriot’s Continued Success
Here at Ferriot, we pride ourselves on being able to support our local economy and for helping to promote positive change for the manufacturing industry. Ever since our start in 1929, we’ve been able to provide custom mold manufacturing, injection molding, and a host of other manufacturing solutions for a variety of markets by focusing on adaptability and innovation.
At the onset of the COVID-19 pandemic, Ferriot was deemed an essential 
business. With many of our customers in medical, financial, and industrial markets, we were given the chance to continue operations during the shutdown.
Through new safety measures and organizational processes, Ferriot has maintained employment levels, while remaining focused on keeping our employees safe and healthy while continuing to support our customers’ supply chain. Most importantly, we at Ferriot have continued our mission of aligning the right people with quality processes, resulting in the flexibility and adaptability to meet the changing needs of our customers and fluctuating market conditions.
In these last five years, Ferriot has made a significant effort to reinvest in the people, technology, and equipment that have fueled our success. Last year, in 2019, we achieved our biggest sales year to date.
Together, we came up with a single word to help us all focus on our goal: Excel. To truly make a difference, we must empower each of our employees to use their own skills, creativity, and ingenuity to help improve the day-to-day operations of our business.
We cannot just do good enough – we must Excel.
People First
The first step on the path to excellence is our focus on people. Both our technical specialist and management teams must be given the proper training and ongoing support to do their best work. Teams must also operate harmoniously, empowered by the goal of continued excellence.
To support our teams, Ferriot has added key talent in technical areas to help reinforce our engineering support with quality process improvements to allow us to better serve our customers. All levels of management have also received leadership training, specifically that in working with cross-functional, technical teams.
Advanced Tooling and Technology
The right team needs the right tools. That’s why Ferriot makes certain to provide our employees with the best and most up-to-date equipment to help them identify and solve problems.
In 2015, Ferriot invested in new ERP Software, IQMS. This advanced software gave our teams real-time data and visibility into better managing day-to-day operations while maintaining business continuity.
We also make sure that our machinery is up to the tasks at hand by regularly reinvesting back into our operations, replacing aging injection molding machines and equipment with newer models. In 2018, we added our largest injection molding machine yet: a 2250-ton press. With press sizes ranging from 66 to 2250 tons, Ferriot has the flexibility to run a large range of products in-house, helping us to maintain quality and performance throughout our offerings.
Excellence for the Future
One big way that Ferriot is planning for the future is by investing in automation and new manufacturing practices. By testing out advanced mold flow analysis software, digital scanning technologies, and collaborative robots that can work alongside human operators on the manufacturing floor, we’re making every effort to set ourselves up for future successes.
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If there's one thing that every manufacturer knows, it's the value of a good operator. Operators are champions of production, driving the performance, efficiency, and reliability of your plant processes.
Unfortunately, great operators are often wasted on repetitious manufacturing processes, where most of their time is spent on mundane tasks instead of work that requires more "brainpower" and finesse. On those monotonous tasks, if operators are being forced to act like a machine doing the same thing over and over again, why not get an actual machine to do it?
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What's more, is that all these things can happen while also improving the jobs and lives of the operators. Contrary to popular belief, cobots weren't made to replace operators but rather enhance the workflow and save them for more important tasks.
Here's why Ferriot and other manufacturers are turning to the power of cobots to enhance plant productivity.
Cobot and Ultrasonic Welding Service
The High Cost of Manual Labor
A lot of manufacturing is doing the same thing over and over again. Unfortunately, humans weren’t made to do the same thing time after time with perfect reliability.
This lack of repeatability with human labor leads to significant inefficiencies over time, forcing manufacturers to accept a certain amount of lost time and bad products. It is human nature to find shortcuts, and people get bored doing the same thing over and over. There's no value-added benefit of having people in control of these tasks. It leads to reduced quality and the need for more labor.
When an operator has to do every mundane task on the plant floor, it also forces unneeded wear and tear on their bodies. This leads to operator burnout, which is not only a hazard to their personal lives but can cause them to underperform at work.
Overworked operators also don’t have the time to critically analyze the parts they're creating, which is bad for quality assurance. Operators are just moving parts and not really looking at them.
Cobot and Insert Welding Service
The Power of Cobots
With the power of today's technology, manufacturers no longer have to rely on human operators to handle every production task. Cobots can now handle all the repetitive and tedious elements of manufacturing, leaving operators open for more complex tasks and part analysis.
Not only does this save time on assembly, but it also leads to higher quality and more consistent parts. Manufacturers looking to add cobots to their production lines can expect measurably better parts, sometimes in half the time.
None of this should be worrisome for the operator, as many often misconceive that a focus on manufacturing robots and automation will take away jobs from the people that previously did those tasks. Cobots are collaborative robots. They don't take away jobs so much as they take away the bad parts of jobs, allowing operators to be happier, healthier, and more productive as they oversee the cobots and focus on more skilled work.
Ron Pack, Manufacturing Engineer at Ferriot, talked about the importance of cobots in a recent interview. "A person has to be involved somehow in almost everything with cobots, so you’re not taking away any jobs or disrupting operators," said Ron. "But the more you can automate the mundane parts of manufacturing, the more your operators can look at the finished product and make sure it's actually good. Operators are happier, and your parts are better. It's a win-win."
Better Manufacturing at Ferriot
Seeing the value that cobots offer to both manufacturers and operators, Ferriot has invested in new cobot technology to aid Ferriot’s team on the plant floor. Since the beginning of 2020, Ferriot has employed two cobots to assist our operators and improve our facility's performance.
Currently, Ferriot's cobots are working on six different parts, with plans to add four new parts to their workflows in the near future. "The increased efficiency and repeatability of the cobots has really been key," said Ron. "In some of our more important areas, we’ve seen efficiency gains of 60 percent or more."
Cobots have been a particular help in recent times due to the COVID-19 pandemic. They've allowed Ferriot to reposition its operators to better handle the changing environment in a time where recruiting new operators was difficult.
One thing is for certain – cobots will play an increasingly bigger role in the manufacturing plants of the future, creating better working environments for operators and manufacturers alike.
Is Your Culture a 'Good Fit' for New Technology? [Industry Week, Craig Ferriot interview]
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It is important for designers to consider product requirements when parts are being designed for ultrasonic assembly. Joint design and resin selection decisions are impacted by these inputs.Ultrasonic welding requires specific areas of the parts to soften but not melt with increased temperature. This is why thermoplastic polymers and not thermosets are used for this application. Two main types of thermoplastic polymers exist – amorphous and crystalline. Amorphous polymers work best when using the ultrasonic welding process. Here’s the difference:
Amorphous polymers do not have an organized molecular structure or a defined melting point. When heated, they gradually soften as they pass from a rigid state, through a glass transition, into a rubbery state, followed by a liquid flow in a true molten state. Solidification is likewise gradual. Crystalline polymers have a more organized molecular structure which causes the material to absorb vibration energy before it can be passed through to the joint area. This means more power is needed to weld them, and they have a sharper melting temperature. This causes difficulty in making a quality weld without damaging the parts. ABS, Acrylic, Polycarbonate, and PVC are amorphous polymers - with little or no crystalline structure, they are ideal for ultrasonic welding. Polyethylene, Polypropylene, Polyester, and Nylon are semi-crystalline and are still used in the ultrasonic welding process but are more difficult to weld.
For optimum assembly results, the three basic requirements when designing a joint are a uniform contact area, a small initial contact area, and a means of part alignment.
Ultrasonic welding of plastics is a reliable, consistent, repeatable process that provides a clean, strong, integral bond. The benefits make it widely accepted in many industries, including automotive, medical, electrical, electronics, communications, appliances, and consumer products.Injection molders who offer this value-added service work closely with design engineers and ultrasonic welding experts to find the most cost-effective solution yielding quality parts. Understanding design requirements for parts to be assembled can allow for a well-designed tool that produces superior results. Avoid NPI delays and tooling rework by involving your injection molder upfront.
Do you have a new product with multiple components needing assembly? Contact Ferriot to help you ensure a successful product launch.
In Part 1 of our discussion of the importance of TQM to the injection molding process, we introduced George Popov, our Quality Supervisor, and provided you with a behind-the-scenes look at what George and the Ferriot Quality Team are doing to implement and improve TQM on a daily basis.
In Part 2, George and I discuss a new technology acquisition, the AICON smartScan Structured Blue Light Scanner, and how it is helping Ferriot meet and exceed quality goals.
Liz: Tell me about this new scanner. How long have you had the scanner in-house and how are you using it?
George: We've been utilizing the new scanner for about 18 months. The AICON smartScan is a new state-of-the-art piece of metrology equipment that helps us to accelerate the injection molded part development process. It’s a blue-light scanner, that works in conjunction with PolyWorks inspection software. It enables us to scan physical parts into 3D images that can then be overlaid to the CAD model for that part and inspected very thoroughly.
One of the greatest benefits this provides is the color map comparison feature, which provides instantaneous visual results and allows us to see what is going on with the part before ever taking a single measurement. The color map provides a real indication of the distance between the actual part versus the CAD nominal surface. This is of great benefit to our customers, because it helps quickly solve any issues they are experiencing in the very early stages of part development and verification during the approval process.
Liz: How has that scanner helped the engineering and quality teams do their jobs better?
George: The scanner has the most direct impact on our quality department as a whole, but it’s especially valuable to the project engineers because they’re able to look at real-time data, visibly seeing critical details of a part that has been scanned. Right away, they’re able to tell where the problem points are going to be when we mold these parts in-house.
Most of the time we will actually get samples along with a transferred mold tooling. In fact, a lot of the molds we have are transferred tools, so we frequently get parts from different countries all over the world. We scan them and can see where they're at quality-wise before we actually mold parts with them—so we have something to compare to. If necessary, we can make quality improvements to the mold that’s been transferred to us, so t's been very helpful in that aspect.
Ferriot’s AiCON smartScan scanning an injection molded part using blue light scanning technology. Blue light 3D scanners offer better precision, accuracy, and higher quality outputs than white light scanners, laser scanners, and CMM.
Liz: I can imagine that saves a lot of time and aggravation! You told me that this scanner replaces about 80% of what used to be done with the Coordinate Measuring Machine (CMM). What is still being done with the CMM?
George: The things that are being done with the CMM are only the parts that we are not able to scan. What I mean by that is, with the scanner, what you see is what you get. If the cameras can see the features that you're trying to attain, then it will be able to measure them, or it will be able to capture an image.
However, if the cameras cannot see a feature such as deep channels or bosses, it does not do well with that because it can only scan so deep. Then we would put those parts on the CMM. In fact, the scanner and CMM can work together. You can do part of a program on the scanner, and whatever you can't get on the scanner, you can do on the CMM, which also saves us quite a bit of time.
So yes, we're doing much more on the scanner. That is our main device for gathering data now. Our CMM is pretty much our secondary or backup machine. We still utilize CMM. Actually, there are parts that we do on the CMM for programming purposes because it’s easier. Between the scanner and CMM, we have the flexibility to pick which is best for the project.
George Popov, Quality Supervisor and Walt Kravetz, Quality Technician, reviewing smartScan data in PolyWorks Inspector software.
Liz: Any interesting quality success stories since you've been at Ferriot?
George: One of the first customers we started doing scanning work for saw the data, and they came in and wanted to talk to us about what they thought was inconsistent data. They thought, they better make sure this scanner works because it's a new system and the data looks questionable.
What we were able to prove is how warped their parts were, and how it wasn't the scanner, it was actually the parts themselves that were so different. When comparing from part to part, they varied so much. I was able to show them that with the PolyWorks software that works in conjunction with our scanner. We could easily zone in on specific areas with which they were having concerns, and show them why they were having problems with them.
We were able to overlay the scan model over the CAD model and apply a color map. By manipulating the scale range for that color map, you can have a tighter tolerance to see where parts are out of spec, and how closely the scan model correlates to the CAD model.
By comparing the new scanner data and addressing their concerns, we were able to prove to them that the PolyWorks software is more than capable of giving them the precise, accurate data they needed. They were very satisfied with what we showed them, and their confidence level in our capabilities were established. They walked away satisfied with what we were able to do, and they felt comfortable that the data we gave them is good data. The fact that they can see the areas of concern without us even taking measurements was a huge deal for them.
Liz: Tell us a little more about the PolyWorks software and the value that it brings to the process as well.
George: Once scanning is completed; a mesh is created and then an STL file is used to inspect against a 3D CAD model in PolyWorks software…
Liz: …And what is the STL file and mesh that’s created?
George: Well, STL is short “Standard Triangle Language” and “Standard Tessellation Language.” STL (or STereoLithography) is an openly documented file format for describing the surface of an object as a triangular mesh, that is, as a representation of a 3-dimensional surface in triangular facets. We use the STL file with PolyWorks Inspector.
Liz: Ok. So, then the STL file is used with PolyWorks in what ways?
George: PolyWorks Inspector is a universal 3D dimensional analysis and quality control software solution. By using it with portable metrology devices like our SmartScan, we control tool and/or part dimensions, diagnose and prevent manufacturing and assembly issues, guide assembly building through real-time measurements, and oversee the quality of assembled products. The scanning software allows for smoothing and filling in of areas not scanned, based on triangulation and geometry of surrounding areas attained by scanning.
PolyWorks Reviewer is an easy-to-use software application that can be utilized by Ferriot’s cross-functional teams or even our customers in order to visually assess the injection molded part and any areas of concern. Put simply, Reviewer enables manufacturing specialists to dig deeper into the measurement database to analyze any dimensional issues highlighted by a metrology specialist. In Reviewer, controls can be searched, sorted, or filtered in the user-friendly Control Review Interface.
View of AICON smartScan data in PolyWorks Inspector universal 3D dimensional analysis and quality control software.
Liz: Previously, we talked about SPC and graphs. What is SPC and how is it used?
George: Statistical process control.
Liz: And you were saying that we could graph now, and apparently, we couldn't before. Is that correct?
George: Correct. It's a huge plus, and I think more and more companies are going towards SPC because it really gives us the tools to be able to control processes out on the production floor. That's what we're really geared towards—controlling processes. You can see on the graph when things get out of control, then you can make the call, “Hey, something's going on here, we need to get this thing back into control.” And then you can follow the graph and see your trends. Trend charting is huge and adds a great deal of value.
That's actually another thing I'm working on with the inspectors: I'm having them look at their trend charts to see how things are measuring on a day-to-day basis, and at production run after production run. As a result, we have that data now. The big deal about having this electronic database is being able to chart everything, being able to look at what they're inspecting. The whole visual aspect is very key. That's a big deal for us, and for our customers.
Liz: One last question. As quality supervisor, how would you describe the Ferriot advantage to a potential new client?
George: Well, that's a good question. I would say the Ferriot Advantage is that we are moving TQM in a direction of total customer satisfaction—from their supply chain and procurement people to the design engineers and quality control manager. Part of that is acquiring state of the art equipment that gives our customers, not just a warm and fuzzy feeling, but absolute confidence that the data that we provide them is accurate and precise.
Why? Because they're be able to see everything. It's a very visual system. And I don't know about you, but when I'm looking at a big spreadsheet of numbers, it’s easy to get lost quickly. But when I'm looking at a visual map, something easy to interpret with the eyes, then I don't need to guess where things were measured. At what point was this measured? How many points were taken to create this feature? Everything is visual. It’s right there in front of me. And it gives a very quick indication of the overall quality of the customer parts.
In turn, that allows us to make quick decisions on how to proceed. If the part is good, we can see that right away. And if not—if there needs to be tool modification—we can make adjustments. We can do it quickly. No surprises. We don't have to sit down over spreadsheet after spreadsheet and try to make an educated guess on which way to go, because that's very costly. In the end, it comes down to saving time, cost, and quality, all of which are reflected on the bottom line.
We not only want to get things out in a timely manner, but in an efficient manner. We don't want to just read through things and give data that we're not sure of. When we can put a color map and data side by side and it just jives like that, it gives everyone a good feeling and confidence that the support we're going to give is going to be second to none.
[post_title] => Importance of TQM to Injection Molding Projects - Part 2 [Interview] [post_excerpt] => Learn about benefits a new scanner/quality inspection software brings to Ferriot injection molded parts TQM in this interview with our Quality Supervisor. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => importance-of-tqm-to-injection-molding-projects-part-2-interview [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:11 [post_modified_gmt] => 2024-03-11 20:11:11 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-importance-of-tqm-to-injection-molding-projects-part-2-interview/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [36] => WP_Post Object ( [ID] => 2314 [post_author] => 3 [post_date] => 2020-06-18 15:39:00 [post_date_gmt] => 2020-06-18 20:39:00 [post_content] =>
Total Quality Management is critical to everything we do for our customers. At the end of the day, the goal is production readiness. Injection molded parts must be optimized for functionality, production consistency and ease of manufacturing. TQM includes everything from start to finish, from mold qualification to production quality.
However, for many of us at Ferriot, TQM is also our way of life. This is especially true for George Popov, the Quality Supervisor at Ferriot. George was able to take some time out of his busy schedule to discuss how Ferriot is dedicated to the process of continuous improvement when it comes to delivering quality to our customers.
Liz: How long have you been working in the quality field and with Ferriot as the quality supervisor?
George: I’ve been working over 10 years in quality. It’s getting close to three years with Ferriot, with about 10 months in a supervisory role.
Liz: What do you do at Ferriot as a quality supervisor?
George: I oversee the inspection team for both the molding and finishing departments. And I provide them with support on any issues they're facing, direction on how to perform their responsibilities. Of course, there’s much more, but that's basically what I do.
Liz: How large is your team?
George: It's a four-person inspection team, with a backup inspector for each shift in the Molding department and two backup inspectors for the Finishing department. Having someone available during all hours of operation emphasizes how important delivering quality is for Ferriot.
George Popov, Ferriot Quality Supervisor, reviewing in-process inspection dimensional trend charts with First Shift Inspector Markeet “Angel” Bradford.
Liz: What is involved with your position and responsibilities as the quality supervisor?
George: Of course, I’m making sure our inspectors are putting quality matters first and getting the right answers to anything that they might have questions about to assure we’re delivering the highest quality end products possible. However, it’s also about giving them guidance and direction on how to perform their responsibilities, and supporting them when they run into issues on the floor, or internally, and giving them the support that they need to make sure they feel comfortable doing their jobs.
Liz: How frequently do you interface with customers directly?
George: Whenever we have customer visits, typically that's with our quality director and quality engineers. I make an effort to go out of my way to be sure I meet them, the customers, just so they know who I am, and in case they need to see me in the future. They need to know I’m accessible.
Liz: Describe what your work day is like at Ferriot as the quality supervisor.
George: My schedule is from seven to four, just so I can connect with the third shift inspector when I come in before she leaves. I'm here all day first shift, and then on second shift I also overlap with the second shift inspectors so that I can communicate with them in person, at least for part of their shift, to discuss any concerns and go over any pressing issues. I periodically check my emails to see if there's anything that I need to address immediately, what I can put on the back burner for things that are not so pressing. I always make sure to get back to everybody as quickly as I can, but also as efficiently as I can.
I spend a lot of my time looking at inspection inputs, going over any issues with the inspectors, especially with my first shift team since I'm here most of the day.
I also make an inspection round on the floor and I'm increasing that as well, just so I'm aware of what's happening out there in the molding department. I'm trying to be sure I have a feel for everything that goes on and where our quality team needs to place the most focus.
There’s also a lot of correspondence with cross functional teams, with the manufacturing department, the front office personnel, a lot of contact and correspondence with all the Ferriot engineers. I support them with issues that are occurring on the floor, helping them put out “fires” as they arise, helping them put together work instructions, quality alerts, and relaying critical information both internally and to customers. I’m the interface between the quality engineers and the inspectors. That makes up the bulk of my day.
Throughout the day, I’m also working on different quality department improvements. For example, we've moved away from an old paper system for inspection records to our online IQMS inspection. That's been a challenge, but a good one. Transitions are always painful, but we know that they can be beautiful in the end.
Liz: It sounds like you have a number of hats to wear, and it's an ongoing process of improvement, which is excellent to hear. Can you speak briefly about the advantages of that shift to IQMS you mentioned?
George: Absolutely. It's just everything can be saved electronically now, so we have ease of access to all our inspection records. We also have SPC (statistical process control) available that we chart everything now so we can see trends. That helps us tremendously with process control on the manufacturing floor. When we see a process shift on our graphs, we can alert the manufacturing personnel so that they can make adjustments and take notes—something our old paperless system did not allow us to do.
With the old paper-based system, a lot of information was just put in storage. No one really saw what was happening unless a big issue would arise. And then it could really get ugly. We still have that paper system as a backup in case our system goes down, in case we lose power, or what have you. But it was just an archaic way to document our data and our customers were noticing that. It just wasn't something that gave our customers confidence in us.
Now that we've gone electronic, it has caught our customer’s attention. They can see that, yes, we do care about quality, and we do care about the data we collect. It's not just going to be put on paper and filed away. Everything's documented, it's very visible, easy to get to for review, and I think it's just the right thing to do.
George and Quality Technician Walter Kravetz reviewing scanned model from the AICON smartScan Blue Light Scanner (by Hexagon Metrology) within Optocat software, before sending the file over for dimensional analysis in PolyWorks Inspector universal 3D dimensional analysis and quality control software.
Liz: What would you consider to be your biggest challenge on a day to day basis?
George: That would be making sure I have buy-in with our people. It is very important to get our inspectors on board with why we're making changes. I know it's been a challenge. They've been used to a paper system for many, many years. And now this change with new structure and evolving process improvements. Getting them through the transition period was a very difficult challenge. Some days are really good, and some days won't be. But we continue to get through those challenging times. I also seek advice from other people, cross functional teams, and from my director. He's been a good mentor for me.
It’s a valuable thing—learning how to deal with the challenge of transition and ongoing process improvements. If I can focus the inspectors on why we're doing this so that they can see the vision as well, hopefully everyone appreciates the resulting benefits. Right now, it's kind of hard, but we're hitting several milestones. We're understanding the system more and more each day. And I think that's obviously making it easier for them to get on board. Sure, there’s still challenges. You’ll eventually run into something you haven't run into before. We'd like to fix everything right now, or yesterday. But it just doesn't happen that way. However, we're chipping away at things each and every day and it shows in our ever-improving quality.
Liz: And I'm sure it's going to provide great value to our customers in the long run.
In Part 2, we’ll discuss one of Ferriot’s new technology acquisitions, the AICON smartScan Structured Blue Light Scanner by Hexagon Metrology, and how it is helping the Ferriot Quality Team deliver quality like never before.
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A practical way to provide design flexibility - A smart way to reduce cost
Gas assist injection molding (GAIM) is an enhanced injection molding process often applied for complex parts, large parts and parts requiring an attractive, cosmetic finish. The types of parts benefiting most from this process include:
The gas assist process is introduced at the finish of the mold filling stage while the resin is still liquid. Pressurized gas (usually nitrogen) is used in place of pack pressure from the molding machine. The pressure from the gas completes the filling of the mold cavity, forcing an even distribution of molten resin against the mold. The gas is held inside during the entire cooling phase and then is vented, leaving a hollow void. For internal gas-assist molding, the void is inside the plastic. For external gas assist molding, the void is on the outside surface, typically the back side of a part.
Benefits? There are many.
The gas-assist process gets results when part design elements make the part difficult to manufacture using straight injection molding. GAIM allows for more design flexibility while still being able to provide these benefits:
Design Advantages with Gas Assist
1. Complex Designs
For the design engineer, using GAIM expands design options and helps to minimize design changes to make the part manufacturable using injection molding. One of the greatest benefits is the ability to produce complex parts. Oftentimes with straight injection molding, parts having different wall thicknesses are molded separately and assembled later.
GAIM allows multiple parts to be combined into one, reducing the need for secondary assembly processes – even if the parts have different wall thicknesses. This is because gas-assist allows heavy wall sections to intersect thinner ones. Support ribs and bosses can achieve tighter tolerances and be designed larger without fear of sink marks. Gas channels are directed toward these areas and the consistent pressure during the cooling phase eliminates sink marks, associated with these support features, on the front side of the part.
2. Metal Replacement
Gas-assist allows production of thin-walled components that have solid but hollow areas. The resulting strength and lightweight part can often replace metal fabricated or die cast parts, and reduce product cost.
3. Large parts
The introduction of gas pressure aids in mold filling, providing uniform pressure throughout the part that lasts through the cooling stage. The result is a part with less shrinkage and reduced warpage. Part weight can also be reduced by creating hollowed out areas.
4. Cosmetic finishes
Where an attractive finished surface is required, gas-assist prevents sink areas which eliminates or at least minimizes secondary operations to improve part appearance including sanding and priming.
5. Hollow parts
The gas can create hollowed out areas within parts like handles, which decreases part weight and still provides strength.
Cost Benefits with Gas Assist
1. Extended Tool Life
With gas-assist, lower clamping force is required because lower pressures are used. This results in less mold wear extending the life of the tool.
2. Less Energy Cost
With lower clamping force required, larger molds can be used in smaller presses. Smaller presses consume less power and help to decrease the cost of manufacturing the part.
3. Less Machine Time
A more rapid cooling period helps to reduce cycle time which in turn lowers manufacturing expense per part.
4. Lower Material Cost
Less material is used to produce the part because hollow areas inside of the part are created with the gas and with less resin used, part cost is lowered.
5. Quality Results
With gas-assist injection molding, the process is typically easier to control than conventional injection molding. A dependable, repeatable process provides consistent production results and less waste.
Gas Assist Tool Design
If you want to achieve high quality results, make sure you get the tool design right.
Regardless of what injection molding process will be used, it is important to engage your molder during the early stages of part design in the design for manufacturing (DFM) phase. Tooling cost, timeline and resulting part quality will be directly impacted by the quality and efficacy of the tool. When determining the optimal way to mold a part, engineers will consider all product requirements including application, resin selection and cost considerations. Mold flow analysis is used to find design constraints so that adjustments can be made. When the tooling engineer determines gas-assist is the best solution, the tool will be designed with gas channels built in to the mold that will allow the addition of nitrogen gas during the molding process. Determining your molding method early will conserve tooling cost and help to maintain project timelines. Getting your molder involved early will be critical to a cost effective, high-quality product.
To learn more about this process or to receive assistance with your project, contact Ferriot.
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COVID-19 has drastically changed the way that companies are run – possibly for years to come. Here in Ohio, we’ve all had to change the way that we work and go about our lives.
While stay at home orders are starting to slowly lift, that doesn’t mean a quick jump back to normal. As an essential business, Ferriot has remained open during the quarantine, making critical parts for the medical, industrial and financial services industries. However, it’s how we all protect our workers that’s equally as important to fighting the pandemic.
As businesses start to open back up again, Ferriot is focused on safety, both for the health of our team and for the well-being of our community. By closely following the guidelines and recommendations set forth by the leading health experts, we can work together to resume business the safe and smart way. The right way.
For over 90 years, Ferriot has always made certain to protect the lives of our workers. Now more than ever, with over 140 employees, we are committed to keeping our people safe. From canceling employee gatherings to increasing our efforts in free worker resources and our employee assistance program, we don’t plan on letting up on our updated safety policies until the pandemic is over. Other company-wide efforts include:
It’s these kinds of policies that put our workers first, so that they can have the security and peace of mind to focus on making essential medical parts, including one that is currently being used in rapid diagnostic devices that will test for antibodies of COVID-19. We’re proud that not only can we help support public health with these critical pieces of medical equipment, but that we can start that initiative here at home. This kind of mindset is what we were founded on, and what we promise to continue in these difficult and uncertain times.
In addition to these efforts, we are also doing our best to help out others in need and those on the front lines of the COVID-19 response:
After making sure that everyone on our team was properly equipped with preventative gear, we were able to supply the Akron Fire Department with over 100 N95 respirators to use as they work hard to keep us all safe.
Ferriot was also pleased to be able to help out a service provider in personal way. Because we added additional cleaning services in the office during the day, our office staff was able to meet a member of our cleaning crew. Employees got used to seeing her around and noticed her intently working on her phone. The staff found out she was taking her online classes with her cell phone because she did not have a computer at home. We were in process of replacing some computers and wanted to give her one. Our IT staff repurposed a computer for her to use at home.
These kinds of acts are something that any business can do, no matter their industry.
We are doing all of this to make sure that safety is our top priority. There is nothing more important than the health of our workers, our community, and our families. Period.
From everyone on Ferriot team, we hope that you and your loved ones are staying safe.
For more information on how to protect yourself and those around you from COVID-19, please refer to these guidelines from the CDC.
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Since 1983, I have made my career and fed my family by being that most misunderstood and maligned of professionals – a “salesman.” Except for a seven-year stretch when I worked in an office in Midtown, I have worked from a home office.
During happier times, I used to get a lot of, “What is on TV now?” being asked at 10 a.m. I reply, “Watch out what you wish for. When you work out of your house, you are always at work.” That usually shuts them up.
Read the full article at Cleveland.com.
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Team Ferriot recently enjoyed a visit from students at Akron's NIHF STEM High School. The students toured our 200,000-square-foot office and manufacturing facilities to learn more about the latest manufacturing processes, technologies and varous injection molding career opportunities from engineering design to quality management. The following photo blog provides you with a glimpse at their tour.
Ron Pack, Manufacturing Engineer, provides students with several new technology demonstrations, including collaborative robots (cobots) that assist with repetitive tasks and allow employess to do more complex work.
Students controlling the cobot using hand held touch screen. In this case, the cobots handle the repetitive task of moving the two parts to the ultrasonic welder (not visible in the photo). This permits employees to focus on tasks requiring more "brainpower."
In the color lab at American Original Building products, Mona Melton, Quality Technician, takes the students on a tour of the quality inspection area. Special software is utilized to check color samples from production runs of injection molded shake siding for homes.
Mona discusses siding features and color inspection with the STEM school students.
Numerous Engineering Services including Design for Manufacturing (DFM) and product design assistance are discussed. Here the student is looking at the 3D images of an injection molding tool design.
A STEM student studies a part with the advanced CAD software used by our Engineering team.
Marc Keeler, General Foreman, discusses several finishing operations in the paint finishing area.
As part of a Total Quality Management (TQM) exercise, students work with Quality Supervisor, George Popov, measuring parts to determine if the parts are within specification tolerance.
Aaron Dadisman, Molding Manager, explained how the molding process works, beginning with the resin pellets, emphasizing how important resin selection can be to the final product.
Aaron Dadisman further explained the molding process at one of the larger presses.
Walter Kravetz, Quality Technician, demonstrates the scanner technology used to ensure parts meet design specifications as parts of Total Quality Management (TQM).
Walter demonstrates how a CMM machine (coordinate measuring machine) measures the geometry of a part.
Dale Leopold, General Manager, spends time with students In the product testing area, where students are given the opportunity to give siding from American Original Building Products a rough time.
Student participates in an impact test to determine if siding strength meets specifications.
Training is an ongoing process for anyone choosing a career with Ferriot. Students were given an opportunity to ask the Ferriot experts questions about injection molding, engineering services, and other career paths.
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This past week, Ferriot enjoyed a visit from students at Akron’s NIHF STEM High School where students had the opportunity to learn how things are made and to see what a potential career in manufacturing looks like. Guided by Ferriot employees, students toured the facility and received a hands-on experience while learning about technologies used in manufacturing.
According to President, Craig Ferriot, “The campus visit by NIHF students last week was both exhilarating and rewarding for all our associates. Everyone here took great pride in sharing what they do, as well as highlight some of the advanced technology they work with every day. The students were interested in finding out what types of products we make and how they’re made.”
"By the look on their faces, I thought we were highly successful in dispelling the many rumors around how a career in manufacturing is anything but the dirty, greasy and nasty unskilled environment they may have thought it was,” Ferriot stated. “In fact, they found out just how technically advanced some jobs really are because of the integration of different types of highly automated equipment, robotics, computer aided design and analysis software, error detection systems, scanners and testing systems utilized in the manufacture of products today.
“In many ways, this event enabled our employees to convey their passion in such a way that these young professionals could understand and connect on a different level with today’s environment in manufacturing.” Ferriot concluded, “Our goal, is to help shine a light on manufacturing in such a way that young people are better informed, comfortable and energized to someday seek careers in manufacturing right here in Akron, Ohio.”
The Ferriot Team commented on the experience:
In our next blog, we'll share several photos of the STEM school student's tour of Ferriot and share some additional information on the processes and technologies they had a chance to see firsthand.
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Here at Ferriot, an increasing number of our clients are expressing growing concerns over the Coronavirus crisis and the impact of this crisis on the global supply chain. The situation remains very volatile, changes daily, and continues to have a global impact.
This affects injection molding because the industry relies heavily on Asia, especially China, to manufacture a significant portion of the tooling. A large percentage of plastic parts are molded there as well. The lower labor cost has allowed Asian countries to deliver tooling at a lower cost and provided OEMs with a reasonably safe supply chain.
Because this pandemic began in China, the Coronavirus crisis is causing production disruptions and serious shipping delays—some beyond 12 weeks. Many manufacturers and OEMs are struggling to keep their supply chains moving. Companies don’t know when workers will return, when plants will be running again and when parts will be made.
The supply chain from Asia to support US manufacturing has become a big question mark.
As a trusted American manufacturer based in Akron, Ohio, Ferriot provides an alternate solution to manufacturers that will keep production going:
If you're realizing that it's time to place the production or assembly of your key parts with another company, you'll want the transition to go as smoothly as possible.
To get you started, download our guide, "5 Key Considerations When Transferring Molds to a New Custom Injection Molder" to learn how to:
Click the button to get your PDF checklist.
Don’t wait for the crisis to get worse. Consider transferring your tools to Ferriot. We’re here to help smooth the transition and keep your production lines running.
Contact Us today if you have any questions or need additional information.
[post_title] => Stop Coronavirus Impact On Your Supply Chain [post_excerpt] => Coronavirus concerns impact injection molding because of industry reliance on China manufacturers. Keep supply chain running. Consider transfer tooling. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => could-the-coronavirus-impact-your-supply-chain [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:12 [post_modified_gmt] => 2024-03-11 20:11:12 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-could-the-coronavirus-impact-your-supply-chain/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [44] => WP_Post Object ( [ID] => 2350 [post_author] => 3 [post_date] => 2020-01-15 14:55:00 [post_date_gmt] => 2020-01-15 19:55:00 [post_content] =>Truth be told, although Ferriot has been around for close to a century accumulating an unlimited wealth of experience and applied expertise, we've really only been blogging for a short time. However, since 2020 marks the start of a new decade, we felt it was apropos to share our TOP 10 injection molding blog posts. The front-runners are determined by you, our frequent readers, after nearly 20,000 views of dozens of blog articles on a variety of topics. The majority of these articles are a quick read, requiring only a few minutes to consume. No doubt you'll find them quite valuable. You be the judge...
Decorative metallic coatings allow plastic parts to function as lightweight, economical alternatives to metals in a variety of applications (i.e. automotive, appliance, business machines, etc.). One such process is electroplating, which provides a high-quality, durable finish to plastic. Today, plating grades of ABS and PC ABS meet the stringent performance requirements of automotive and appliance applications.
This article focuses on two important front end processes, plastic part design and injection molding specifically for electroplating. Both significantly influence the success when plating a plastic part.
Read more...
Are you looking to design, develop, or produce a component that needs to be injection molded to complete the project? Do you know what key aspects you need to identify as you go to design molded plastics? When going into this process, you need to identify both the obvious and not so obvious! Below are 7 items for you to consider before launching your project.
Read more...Today, so many different parts are being injection molded. These parts include laptop and mobile phone cases, medical and military electronic components, and a variety of other materials across industrial, consumer and specialty markets. Because of this, EMI and RFI shielding is becoming increasingly important. Proper shielding for injection molded component parts is necessary to meet regulatory requirements as well as ensure continued, reliable performance.
Read more...
When beginning the process of developing a plastic component through the injection molding process, one of the top priorities needs to be identifying the type or types of resin to be used on the product. While there is opportunity to customize the resins to fit the end use of the part, there are a wide variety of resins available, which opens up unlimited possibilities in design and function.
The first step in the process is to identify the key physical attributes that the end product requires. Below is a list of properties the need to be evaluated...
Read more...When I initially joined the building products industry in 1999 there were 30+ manufacturers of vinyl siding. Fast forward to today, and it’s now down to 9, mostly through consolidation. It remains the #1 choice for exterior cladding across the US, primarily due to its low cost and maintenance freedom. And it looks EXACTLY like it did in 1999. Nothing has changed. People have been driven to this product over the years because it was the closest thing to resemble wood, without having to paint it, stain it, or maintain it.
GOOD NEWS! You have an alternative… Injection Molded Polypropylene Siding, and here are 5 reasons why it's better than vinyl...
Read more...Pad printing is an innovative and effective process for transferring a two-dimensional image onto a three-dimensional surface. It can also be a delicate process with numerous variables that can lead to an unsatisfactory image transfer if done incorrectly. My goal in this post, assuming the reader has a basic understanding of the pad printing process, is to touch on a few of the more frequently encountered problems that cause poor image transfer and how to troubleshoot them.
In my experience with pad printing, the three most commonly encountered problems that arise while printing on a job are as follows: an incomplete print or a print featuring excessive voids, distorted and blurred prints, and the pad carrying excess ink or dirt outside of the desired image.
Read more...
Of course, we've only scratched the surface when it comes to addressing the countless questions, challenges and problems you're facing in order to complete your injection molding projects on-time, within budget, and without sacrificing quality.
Do you have a question you'd like answered but are afraid to ask? Feel free to use the form below or Contact Us and we'll be glad to get back to you. We may even feature the answer to your question in a future blog article or FAQ resource.
All of us at Ferriot wish you a happy and successful 2020!
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The year 2019 was a very special one for the Ferriot team, marking our 90th year in business. Wow! Ninety years! As you can imagine, we've enjoyed learning more about the colorful history and numerous accomplishments of Ferriot's early years. Many on our team weren't aware of our early history with Disney or early Star Wars toys. The year has also been full of reminiscing over family, friends and business associates that have come and gone through the nine years of our existence. It's only fitting to recap some of them by sharing the following 90th anniversary posts from the past year.
Full-service custom injection molder of engineered resins
pays tribute to its long history, with an eye on a bright future
On June 11th, Ferriot began a year-long celebration of its rich 90-year history with a special event for employees at its Akron, Ohio facilities.
Privately held since its founding in 1929, the company spans over five generations of the Ferriot family. In 1999, Ferriot Inc. expanded to its current 200,000-square-foot office and manufacturing facility at 1000 Arlington Circle in Akron, Ohio.
Read more...Company History Highlights by Gene Ferriot (1916-1970's) from steel engraving to injection molded plastics, from Disney characters to Polaroid aviator glasses – a nostalgic look back
In 1916, I started working at the Die Sinking and Machine Company, a machine shop started by my father, grandfather and uncle. I was joined a year later by my brother Glenn. I learned the steel engraving trade and Glenn learned the machinist trade.
After several years we both left to work for the Mechanical Mold and Machine Company, which had been started by four of my father’s former employees. In 1924, I left their employment to start out on my own in the basement of my home on Storer Ave. My brother Joe, who was still attending high school, started working for me in 1925...
Read more...Craig Ferriot’s Speech at 90th Anniversary Event for Employees on 6/11/19
Celebrating 90 Years of Excellence in Building Ferriot’s Future
This is our 90th year celebration. I can't believe it. I've been here a third of it. 33 years! And over the last couple of weeks, I've taken the opportunity to go back and look at some old literature, and I was able to get a lot of information from my dad, my grandfather and some others. I was reminded of all the things that took place at Ferriot that made it successful.
Read more...Our 90th anniversary celebrations continue as Ferriot is the featured story on the front page of this week's Plastics News magazine! Here's an excerpt from the article written by Don Loepp, Plastics News editor.
Akron, Ohio — If you geek out over cool old plastic parts, Ferriot Inc. is worth a visit. The lobby display cases are packed with parts molded in the past seven decades, but they tell only a fraction of the story. Ferriot's full history could fill a museum. Remember hobby horses on bouncing springs? Green army men? Early "Star Wars" toys? Ferriot molded — or made the tools for — all of them. Ferriot also molded big television cabinets back when TVs were real pieces of furniture, not just oversized computer screens.
Read more...Of course, as monumental as a 90th anniversary may be, hitting a milestone like nine decades also provokes thoughts of the future. What can we do to top 90 years. Trust me, we have BIG plans to continue providing ever-expanding custom injection molding capabilities, execeptional value-added engineering services, and stellar customer support. We're looking forward to what the next decade will bring!
In our next blog, I'll share with you our TOP 10 Blog Posts of All Time.
Subscribe to the Ferriot "Plastics & Injection Molding Manufacturer" blog.
[post_title] => Recap: Ferriot's 90th Anniversary [post_excerpt] => Recap of Ferriot's 90 year history as an injection molder / contract manufacturing resource specializing in custom injection molding & engineering services [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => recap-ferriots-90th-anniversary [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:13 [post_modified_gmt] => 2024-03-11 20:11:13 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-recap-ferriots-90th-anniversary/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [46] => WP_Post Object ( [ID] => 2354 [post_author] => 3 [post_date] => 2019-12-11 13:42:00 [post_date_gmt] => 2019-12-11 18:42:00 [post_content] => Is it just me, or did 2019 fly by? Where did the year go? Although Team Ferriot has been very busy this past year, we made sure to cover a number of important topics that help our customers and soon-to-be customers achieve successful results in their injection molding projects. We've covered the gamut, from structural foam molding and custom mold design to ultrasonic welding and selecting custom resins. Below are featured the best blogs of 2019. These are the blogs our visitors, subscribers and customers have read the most in the past year. Enjoy!
When it comes to plastics manufacturing, choosing ultrasonic welding services compared to traditional welding and adhesive methods offers a variety of benefits.
In short, ultrasonic welding is faster, safer, and cheaper than other means of bringing plastic components together.
Read more...Injection molding is a tried and true manufacturing method that has experienced small, incremental changes over the years. It used to be, if you had a product or part to be manufactured, your injection molding manufacturer would provide you with a list of polymers to choose from. Your design and engineering team would work together along with the injection molding team to select a resin that would suit your needs. A variety of factors would be considered including durability, cost, flexibility and cosmetics.
Ready for a secret? It still works like that.
With most manufacturers, you are going to need to select the resin for your part from a list of available options. However, modern facilities have moved into a more advanced method of providing an option not previously available on that list—custom engineered resins.
Read more...In our next blog, I'll share with you our 90th Anniversary Recap.
Is there a challenge or problem you're facing with one of your injection molding projects? Or do you have a question you'd like to ask? Feel free to use the form below or Contact Us and we'll be glad to get back to you. We may even feature our answer in a future blog article. Subscribe to the Ferriot "Plastics & Injection Molding Manufacturer" blog.
[post_title] => ICYMI: Ferriot's Best Injection Molding Blogs of 2019
[post_excerpt] => Our top blogs on achieving successful injection molding projects--structural foam molding, custom mold design, ultrasonic welding, selecting custom resins.
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[post_content] => When it comes to plastics manufacturing, choosing ultrasonic welding services compared to traditional welding and adhesive methods offers a variety of benefits.
In short, ultrasonic welding is faster, safer, and cheaper than other means of bringing plastic components together.
Read on to learn more about what ultrasonic welding is, how it compares to traditional methods and some considerations you should take before selecting a plastics manufacturer.
Ultrasonic welding is the process of converting electrical current into high-frequency ultrasonic vibrations. Those frequency vibrations move so fast that it causes a friction which melts materials together to create a solid-state weld. This process is frequently used for plastics but can also be applied to some metals.
Ultrasonic welding plastic typically takes mere seconds from part insertion to part removal from the ultrasonic welding machine. Other methods of welding require the manufacturer to spend much more time, which also means a higher cost for power and/or fuel. More time is needed to reach higher temperatures for welding, and to allow the part to cool. With adhesives, parts will also need to cure for an additional amount of time compared to ultrasonic plastic welding.
The key downside is that the ultrasonic welds will have a depth of less than a millimeter. So, that means it is not practical in industrial or commercial instruction. However, it’s ideal for manufacturing components in various markets including consumer goods, military electronics, medical devices and more.
When evaluating a plastics production method, risk factors are important to consider. For example, with traditional welding requiring higher temperatures, you have the risk of an open flame and flammable fuels. Also, those fuels and adhesives can create toxic fumes. This means a few things. First, added risk for the manufacturer’s employees. Second, the added cost of additional training, personal safety equipment (PSE) and facility safety precautionary measures.
The high frequency produced by the machine is one key safety concern when using the ultrasonic method. This could potentially damage someone’s hearing, but this risk is simple to mitigate and much less dangerous than risks posed by other welding methods. An ultrasonic welding machine can be placed within a safety cage and workers are required to wear hearing protection.
Overall, when it comes to manufacturing plastic components, it’s easy to see why ultrasonic welding is the preferable option.
Are you working on a project that would be well-suited for ultrasonic welding? If so, please schedule a consultation to learn more about Ferriot’s contract manufacturing services. Or, download our worksheet on Plastics in an Industrial Setting by click on the below image.
Learn more:
Injection molding is a tried and true manufacturing method that has experienced small, incremental changes over the years. It used to be, if you had a product or part to be manufactured, your injection molding manufacturer would provide you with a list of polymers to choose from. Your design and engineering team
would work together along with the injection molding team to select a resin that would suit your needs. A variety of factors would be considered including durability, cost, flexibility and cosmetics.
Ready for a secret? It still works like that.
With most manufacturers, you are going to need to select the resin for your part from a list of available options. However, modern facilities have moved into a more advanced method of providing an option not previously available on that list—custom engineered resins.
Advances are being made relatively frequently in polymers and resins. This is one area where science and technology continue to improve. But, when there are literally hundreds—even thousands—of resins available, why would you need something beyond traditional choices? Read on to learn why developing a custom engineered resin may be the best, most cost-effective way to manufacture a product.
At first, it might seem that selecting a custom engineered resin would cost more than going with a readily available option. While there will certainly be an upfront cost that you would not otherwise incur—the cost to research and develop the resin, this is a one-time fee.
With all the various features to consider when it comes to resins including ductility, rigidity, dimensional stability, temperature tolerance, chemical resistance and more, there are many variations and trade-offs. You might find what appears to be the perfect resin for your product, but it may be in limited supply or material costs could be high.
By developing your own resin, you are better able to control the supply and cut out the frustration of dealing with additional suppliers and middlemen. Also, it may also be possible to have the resin developed in closer proximity to the injection molding plant. This means you may cut down on supply and transportation costs associated with a project.
What if you don’t need all the features of a more expensive resin, but you need an enhanced rigidity? Working with a manufacturer that can custom engineer resin solutions can help meet your needs and save money, especially when you’re dealing with large and potentially repeated production runs. Why pay for features you don’t want?
As previously stated, there are already a lot of options available when it comes to resins and polymers for injection molding. However, certain applications have very specific needs. When designers and engineers are working to produce a part that your business depends on, getting everything right is critical.
With existing resins, you may end up making trade-offs. One resin may have the ductility you are looking for, but may not be electroplatable. Luckily, customized resins can give you everything you need for your specifications.
What if your project has requirements that no one else has brought forth before? That is a case where you would want to work with a resin specialist who can create a resin that fits your product. It’s also important to note that this unique mix may be created just for your company but it could become available to anyone. So, always check contracts, especially if you are concerned with trade secrets.
In manufacturing it comes as no surprise that parts, components and mixtures can vary greatly over time. If you are relying on a specific company for your resin, you are, in a way, at their mercy. If they have production issues, you will have production delays or other problems.
By developing a proprietary resin compound, you have more control over your supply. This may mean working with additional manufacturers to produce enough resin for your projects. It might also mean working to ensure that your resin mixture can continue to be manufactured, even if another company falters or discontinues a resin, filler or modifier. There are a number of sources for base resins and compounding services available. Resin manufacturers may make small changes over time that offer a similar or comparable product, but it is not always the same. If you want the highest level of consistency, you need to be in control of your own resin.
Ferriot, Inc. can work with you to make sure you have the best possible resin for your project. If the resin does not already exist, we will help you create a proprietary resin solution. We understand the demands of high production injection molding for a variety of industries including aerospace, automotive, and medical devices and we will go to great lengths to make sure that your product is the best it can possibly be. Schedule a consultation today to learn more about custom engineered resin or click on the image below to download our workbook on selecting the right resin for your project.
Learn more:
Our 90th anniversary celebrations continue as Ferriot is the featured story on the front page of this week's Plastics News magazine!
Here's an excerpt from the article written by Don Loepp, Plastics News editor.
Akron, Ohio — If you geek out over cool old plastic parts, Ferriot Inc. is worth a visit.
The lobby display cases are packed with parts molded in the past seven decades, but they tell only a fraction of the story. Ferriot's full history could fill a museum.
Remember hobby horses on bouncing springs? Green army men? Early "Star Wars" toys? Ferriot molded — or made the tools for — all of them.
Ferriot also molded big television cabinets back when TVs were real pieces of furniture, not just oversized computer screens.
"Over the years, I think what's really kept the company in the mainstream and relevant is the fact that it's forced to reinvent itself every so often," Craig Ferriot said in a recent interview at the plant.
"We have continued to be innovative, and take the ideas of the past ownership and build on those, and take the original principles of our founding fathers, which was to develop relationships with customers, and how valuable that is," he said.
He's the president of Ferriot Inc., a family-owned injection molder in Akron. The company is 90 years old, but he's just the third generation of Ferriots in the business.
You can read the full article here.
Learn more:
Craig Ferriot’s Speech at 90th Anniversary Event for Employees on 6/11/19
Celebrating 90 Years of Excellence in Building Ferriot’s Future
This is our 90th year celebration. I can't believe it. I've been here a third of it. 33 years! And over the last couple of weeks, I've taken the opportunity to go back and look at some old literature, and I was able to get a lot of information from my dad, my grandfather and some others. I was reminded of all the things that took place at Ferriot that made it successful.
We are here in celebration of what we have achieved together. Without you guys, it wouldn't be possible. Without the people that preceded us, it wouldn't be possible. Without our customer's loyalty, it wouldn't be possible. It wouldn’t be possible without the suppliers that we deal with, your families, who put up with you working every day and doing some things above and beyond. You do that every day, without exception and we appreciate it. So really, this day is for all of you. It is for everything we built together and more importantly, the future and what we could build for the next 90 years.
One of the key things to our success is people. You are the folks that make us successful. And one of the things our founding fathers always said is, “dream big, achieve big.” That is something they lived every day. They didn't settle for conventional. They wanted to solve major problems. I would like to take a moment and share a little bit about Ferriot and our history.
We had some pretty remarkable founding fathers going back seven generations. After coming to the Akron area to work for Goodrich, family members created several businesses and from Ferriot spawned about six different companies in Akron all based around mold making, die sinking and engraving.
Our name was synonymous with our people's talents and what we were able to deliver to our customers. Our customers would have an idea, a sketch and bring it to us. These gifted artisans and craftsmen would take that idea and turn it into a product. They were actually responsible for not only helping to develop and design that product, but how it all fit together and how they had to market it.
There are the three things that stick with me today; that's appreciation for people, pride in our workmanship and what we deliver to our customers, and remembrance. Remembrance of those who came before us and everything that they were able to accomplish and build as a foundation for all of us to enjoy. We're writing our new chapters right now. The key is keep dreaming. Don't settle for something less. Don't be conventional. Don't be discouraged if you make mistakes; that's how we learn. So with that, I'd like to thank everybody for the last 90 years in celebration of what we've accomplished together.
So I appreciate it. Give yourselves all a round of applause.
Learn more:
[post_title] => Dream Big, Achieve Big: People, Pride, and Workmanship in Injection Molding [post_excerpt] => Craig Ferriot’s speech at 90th Anniversary event for employees, 6/11/19. Celebrating 90 Years of Excellence as a premiere injection molding manufacturer. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => dream-big-achieve-big-people-pride-and-workmanship-in-injection-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:13 [post_modified_gmt] => 2024-03-11 20:11:13 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-dream-big-achieve-big-people-pride-and-workmanship-in-injection-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [51] => WP_Post Object ( [ID] => 2364 [post_author] => 3 [post_date] => 2019-08-27 16:07:00 [post_date_gmt] => 2019-08-27 21:07:00 [post_content] =>
Here at Ferriot, we’ve been proud to be a leader in thermoplastic injection molding since the 1940s. Our clients turn to us for professional assistance with contract manufacturing, custom injection molding, painting and assembly. Structural foam molding is another capability we offer when traditional injection molding may not meet part design requirements. The structural foam process creates parts with a high strength-to-weight ratio and is often used for large parts and in metal to plastic replacement.
Traditional injection molding is typically done in two stages. There’s an injection stage where melted thermoplastic is injected into a mold, and a packing stage where pressure is built and the plastic is formed into the shape of the mold. In structural foam molding, the injection stage is basically the same, but the packing stage is augmented by a chemical blowing agent mixed with the material. That chemical blowing agent is triggered by heat and expands the material by creating a microcellular structure at the core with an integral outer skin.
A part built using structural foam molding offers a number of advantages that include:
Structural foam parts generally weigh less and aren’t as dense as similar parts manufactured using other processes. The actual weight savings can vary, but parts built using structural foam molding can be 10% - 30% lighter than other parts. The integral skin contributes to added strength and the entire process creates parts with low stress.
Structural foam molding also scales well, allowing large or bulky parts to be manufactured while still retaining the superior production speed offered by injection molding. Regardless of size, structural foam parts are able to be worked post-production in a manner similar to parts constructed of wood or metal. The surface of a finished part is smooth offering the potential of easy cleaning, and can be painted over.
An additional benefit to parts manufactured using structural foam molding is part durability. As a result of the difference in process, parts built employing structural foam molding are sturdy while remaining rigid, and possess greater internal flexibility than parts built using traditional injection molding.
There are many ways to achieve cost savings when considering structural foam:We’ve been busy putting structural foam molding through its paces to build a variety of parts, including gas pump front fascia. Results have been everything we could have hoped for. Along with the durability offered by the new parts, the material options available for structural foam molding also means a finished product can be chemical resistant, offer electrical or thermal insulation, and can be developed for outdoor applications.
Think structural foam molding is an alternative solution for you? We encourage you to contact us to discover how structural foam molding can benefit your business.
Learn more:
Company History Highlights by Gene Ferriot (1916-1970's) from steel engraving to injection molded plastics, from Disney characters to Polaroid aviator glasses – a nostalgic look back
In 1916, I started working at the Die Sinking and Machine Company, a machine shop started by my father, grandfather and uncle. I was joined a year later by my brother Glenn. I learned the steel engraving trade and Glenn learned the machinist trade.
After several years we both left to work for the Mechanical Mold and Machine Company, which had been started by four of my father’s former employees. In 1924, I left their employment to start out on my own in the basement of my home on Storer Ave. My brother Joe, who was still attending high school, started working for me in 1925. In 1926 I moved to a small shop on Yale Street previously occupied by Freitag. My brother Bert joined me and a little later Glenn came to work with me. We continued operations at this plant until 1932, when we moved to Miller Avenue where we took over the operation of the Wadsworth Core Company which had run into financial difficulty. A number of the Wadsworth employees were put on our payroll and one of them was Jerry Evanitcka. At this time, Ferriot Brothers had about 25 employees, Roy Christenson was also one of them. We continued the manufacture of core machining and repair parts along with core plates and other items used in the foundry trade. At this time, our business was molds and equipment for the rubber industry.
We were the first to make pressed aluminum cavities used in the making of molds for rubber dolls and blown rubber toys of all kinds. Our customers for these molds were all of the doll manufacturers. We built hundreds of molds for the Shirley Temple, Diana Durbin and Didee dolls, and molds for all of the Walt Disney characters. Along with this, we invented and built many machines used in connection with the molding of these parts, and Jerry and Roy were involved in the machining and assembly of these machines during our years at Miller Avenue.
We expanded and prospered even though we were severely hurt during the depression years when all of our working capital was held up for many months by the bank holiday. It was during this period that my brother Bert left us to seek greener pastures on the west coast where he became very successful; he is now retired.
Our lease on the Miller Avenue building, owned by Brown-Graves Lumber, was for 10 years and in 1941 we decided to move to new quarters where there was more room for expansion. We purchased our present building from the City of Akron who had used it for a number of years as the city workhouse. The move meant working in both plants for a number of weeks. As machines were moved, they were converted from overhead line shaft and belt drives to electric motor drives which also meant the installation of bus bar and transformer and switching equipment. We continued in the machining of molds and machining for the rubber industry and added a foundry building which we equipped with gas for crucible melting and later with electric furnaces. We revised the art of making mold cavities using investment cavities progressing from tombasil and nickel bronze to beryllium copper. At one time, we were the largest users of beryllium copper. We developed a line of proprietary items including rotary files, air motors, filters and machinery and rubber presses that were sold under our Power Max label.
During the second world war, all civilian production stopped and we converted to war work, much of which required building the machines used in the production of these new products. We were the largest producers of cartridge dies for small caliber bullets. We machined thousands of tank treads for the Cadillac tank and the amphibious tanks. We made hundreds of oil burners for the Victory and other ships. We machined many parts for the Goodyear Aircraft and other plane manufacturers. I believe we made all of the molds for molding gas masks for the Armed Services, the Navy and a civilian type. We also made molds for the rubber frames for the Polaroid glasses worn by the aviators and many other war related items.
It was during this period that we were hit by a destructive tornado, followed by several days of hard rain storms. We lost most of our roof and had to replace most of the windows. Because of the extreme shortage of labor, it was necessary to make all repairs with our own employees. The resulting clean-up of the plant, machines, work in process, and the rebuilding of the roof and windows, meant many hours of hard work and a herculean effort on the part of everyone. Fortunately, we were able to resume production in a very short time.
After the war we rapidly returned to civilian production, and a gradual change was made from molds for rubber to plastics in the upcoming plastics age. We added a building and started molding plastic by the injection molding process. The first five injection molding machines we built in our own shop which were all of the hydraulic type and Jerry handled most of the the hydraulic work on these machines. We continued the production of molds for toys, and by now they were made almost entirely of plastic. At one time, we had a proprietary line of plastic toys and figurines and several other novelty items.
As our business grew in the plastics field, we gradually disposed of some of our operations such as rotary files, air motors, machinery and presses for the rubber industry and all proprietary items to other companies either thru outright sales or leasing.
In 1952, we hired Chuck Strayer for the drafting department. About this time, the plastic toy molding manufacturing was expanding rapidly, especially those relating to the movies and television. This required the making of hundreds of models and Joe spent many hours both here and at home, and at the same time taught a number of young men the art of model making.
As you all know, Joe was a fine sculptor and a master of all kinds of art. For his contribution to fine arts, he was awarded the world’s highest honors by the Queen of England in an award given to very few men in this country. I am very proud to have started Joe on his artistic career. In our early years, I worked with him in making the models for the dolls and Walt Disney characters. Chuck worked closely with Joe in design work and finding and servicing outside sources of model making.
At this point, I would like to give my brother Glenn recognition for all of the ways in which he contributed to the growth of this company. He contributed a great deal to both the building of molds and machines, and to the expansion of the plant and operation in general. All of you who have worked with him know how of the success and growth of our company he contributed.
Everyone here has been with us 20 years or longer and are familiar with all the changes that have taken place these past 20 years. The changes are continuous in products and in customers and methods. As I wrote this, I was reminded of all the things and events that have transpired during my lifetime. I can remember the real horse and buggy days and the one room school house and how everyone used to run outside to watch one of the new-fangled automobiles go by. It is hard to believe all the changes that have occurred in one lifetime and in the growth of this company over the past 60 years.
Well, enough of the past, what we should all be concerned with now is your future. There will be new markets, new customers, products, methods, machines, talent and growth and it is your opportunity to make it work toward a rewarding and prosperous future for you, your family and your company. This holds true for all of our newer employees also, and it is up to every one of you to help them in every way possible to make a better life for them, their future and their company.
I enjoy being with you and talking to you and hope I can continue for many years. I will be especially interested in seeing what you can accomplish in the future.
In conclusion, I would like to leave you with this one thought. It is very hard to lose old employees and friends. We will miss them, but never forget them, and will be forever thankful for what they were able to contribute to the growth and future of your company.
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[post_title] => Molding History: “Forever Thankful for What They Were Able to Contribute” [post_excerpt] => Gene Ferriot shares his recollections of the company's first 60 years and the people that helped make Ferriot a premiere injection molding manufacturer. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => molding-history-forever-thankful-for-what-they-were-able-to-contribute [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-molding-history-forever-thankful-for-what-they-were-able-to-contribute/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [53] => WP_Post Object ( [ID] => 2369 [post_author] => 3 [post_date] => 2019-07-02 14:49:00 [post_date_gmt] => 2019-07-02 19:49:00 [post_content] => Full-service custom injection molder of engineered resins pays tribute to its long history, with an eye on a bright future On June 11th, Ferriot began a year-long celebration of its rich 90-year history with a special event for employees at its Akron, Ohio facilities. Privately held since its founding in 1929, the company spans over five generations of the Ferriot family. In 1999, Ferriot Inc. expanded to its current 200,000-square-foot office and manufacturing facility at 1000 Arlington Circle in Akron, Ohio.
Although the name may not be immediately recognized, Ferriot Inc. manufactures products that the American consumer sees and touches every day—from ATM machines and gas pumps, to medical devices, jet skis and robots in retail stores. Ferriot also participates in the building products market through its wholly owned subsidiary, American Original Building Products. American Original manufactures a proprietary line of shake shingle siding.
Over the decades, buyers of plastic parts for medical equipment, business machines and industrial applications have learned to rely on Ferriot for their vast engineering experience. Collectively, the Ferriot team has nearly 1,500 years of experience in the injection molding business. Today, the company includes over 150 employees, with an average tenure of 10 years; with 34 people who have over 20 years of service, and 13 people with more than 30 years of service. The longest tenured employee, Bob Hoskin, has been with the company almost 46 years.
“Ferriot has experienced exceptional double-digit growth over the past several years by reinvesting in the business with new machinery, technology and talent,” said company president Craig Ferriot. “We’ve been successful at evolving and changing to stay ahead of other injection molders in the industry. We will continue to position ourselves in the most competitive ways possible to engage with and support our growing list of global clients.”
Ferriot continues, “Moving forward, our focus will remain on investment in infrastructure and new technologies that expand our capabilities and permits production of more complex products. Our continued commitment to the longevity of the company includes growing our engineering staff which allows us to expand upon our tool design expertise that helps bring our customer’s new product ideas to life.”
One example is the installation of the Negri Bossi BI-POWER VH2000-22500 press last year. “This is part of our long-term commitment to increase efficiency, boost labor productivity, simplify workflow, and ultimately deliver the highest quality plastic parts to our customers within budget and on time,” says Ferriot.
Throughout the 90th anniversary year, several events will be held for employees as well as the local community including various academic institutions and community outreach programs.
See the Ferriot 90th Anniversary page here. We'll add new stories and photos to this page throughout the year-long celebration.
[post_title] => Ferriot Celebrates 90 Years as “Your Partner in Plastics”
[post_excerpt] => Ferriot, a full-service custom injection molder of engineered resins pays tribute to its 90 year history, with an eye on a bright future.
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Plastic injection molding is perhaps one of the most popular forms of manufacturing today. Engineers and manufacturing companies from virtually every industry around the world have found that using injection molding to manufacture their products is one of the most cost-effective ways to go.
Cost effectiveness is not merely limited to the initial materials and machining costs, though. Other considerations have a direct effect on this claim including plastic part durability and longevity, customer and client satisfaction, part tolerances and overall labor costs. Read on to learn more about the top 7 benefits of working with an injection molding contract manufacturer.
Injection molding can be used in a wide range of projects. From simple components to parts that have complex geometry and detail, injection molding enables manufacturers and engineers to develop a variety of different parts that are more difficult to make using other molding and machining processes.
The liquid nature of heated thermoplastics and the amount of pressure applied to the resins and molds allows for a high level of detail to be integrated into the molded component. Trying to manufacture parts with the same high level of detail and complexity through other means of manufacturing can be both expensive and challenging.
Once the mold, commonly referred to as a “tool”, is complete, you are ready to produce parts. Injection molding is perfect for mass producing parts as the time to mold a part can be as short as 15-30 seconds. In addition, a multi-cavity mold can produce multiple parts at once or family molds can produce two different parts at the same time, for example the top and bottom of an enclosure.
Most injection molding machines are automatic. They’re programmed for optimal pressure and cool time for each tool. This means that injection molding new parts is a streamlined, repeatable and consistent process. So, you have machines that are designed and programmed to save time, long-lasting steel tools that will allow you maximum production runs and a complete process that runs faster than other manufacturing methods. The efficiencies inherent in the injection molding process means saving both time and money.
There are a variety of standard and custom resins that you can choose for your injection molded components. Based on the needs of your particular product, you can indeed make a part that is stronger yet more flexible than with other forms of manufacturing. Fillers used in the resin mix allow the parts to maintain an increased durability while also boasting a less dense—and thus lighter weight part.
The number of choices when it comes to thermoplastics for injection molding is nearly limitless. The resins can be more or less susceptible to temperatures, chemicals and other environmental factors.
Overall, injection molding allows you to specify the properties of component material. This allows for highly customized units. It also provides parts that last longer in use and under harsh conditions, increasing the value to the consumer.
Injection molding has an advantage in that you can choose to use different types of resins simultaneously during the same molding process. This is done via co-injection molding. This process uses a three-step injection process. First, one type of resin is injected into the mold to create the outer skin or laminate. This is followed by another resin being injected into the core of the mold. Finally, the outer or “skin” resin is injected to fully encapsulate the piece.
The basic premise is that regrind or reprocessed materials serve as the inner core of a part while new resin covers the part. This way you have the same strength throughout, and an excellent outer appearance. Why do this? There are two key reasons. First, injection molding generates little waste. You are using repurposed plastic, known as “regrind” which is better for the environment. Secondly, it lowers the cost of the parts produced, because reprocessed material costs less than virgin resin.
Injection molding is a mostly automated process. That means that a sole operator can manage multiple machines. This means a lower cost in overall labor. Furthermore, while humans remain nearby to run and assist the process, computers and robots handle most of the work. With today’s advanced computer aided design (CAD) and computer aided manufacturing (CAM) software, higher accuracies and tighter tolerances can be maintained.
Another great benefit to injection molding is that it is easy to make the same part using different materials. This will result in providing different aesthetics. Smooth and high sheen plastics are available as well as those that are rough textured. The mold can be textured with the desired finish. While considering options for a part’s finish, also take into account whether the part will need to be painted. Some thermoplastics are ideal for painting while others are available in multiple colors, so painting is not even necessary.
When injection molded parts are completed, they require little to no additional work such as deburring, and other finishing touches required with other manufacturing types. While there is an initial investment in molding dies and design, this cost will be outweighed by the savings in longer and/or recurrent production runs. Instead of making thousands of parts again and again, you make the part once and are able to make copies repeatedly. It is faster and typically cheaper to go with injection molding for a wide range of manufacturing projects.
To learn how to get the most from your relationship with an injection molding contract manufacturer, download our free guide—Designing Injection Molded Parts: A Handbook for Designers & Engineers. Or, if you prefer, call us at (330) 786-3000 for immediate assistance.
Learn more:
[post_title] => 7 Eye-Opening Benefits of Plastic Injection Molding [post_excerpt] => Not sure if plastic injection molding manufacturing is right for your project? For the time and money you could be saving, it’s worth looking into. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => benefits-of-plastic-injection-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-benefits-of-plastic-injection-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [55] => WP_Post Object ( [ID] => 2373 [post_author] => 3 [post_date] => 2019-04-30 12:14:00 [post_date_gmt] => 2019-04-30 17:14:00 [post_content] =>
Structural foam molding is an option available to manufacturers who are looking for a way to create stronger, more rigid plastic parts. It is also a method used to reduce potential part weight for larger parts. Almost any type of resin can be used with this type of injection molding. Structural foam injection molding uses lower pressure and a foaming agent mixed in with the resin. The foaming agent expands within the resin, leaving a dense outer and inner wall with a foam or honeycomb-like center. This cellular core in the part is what contributes to the decreased part weight. During the expansion process, internal shrinkage or "sink" is reduced which creates a more uniform and aesthetically pleasing part. This process can also contribute to less internal stress in the part with better stability.
Overall, structural foam methodology provides a more economical solution than other techniques. It also provides advantages that cannot be achieved using other production processes. The process accommodates intricate designs quite well. Because of the honeycomb interior, parts manufactured using this process also exhibit an increased stiffness-to-weight ratio as well as higher strength-to-weight ratios. Depending on the design, engineering capabilities, and other variables like material choice, the overall weight of the part can be reduced by up to 20%.
Structural foam injection molds incorporate some unique properties that make them
favorable. This technique often makes use of aluminum—rather than steel molds—for parts up to several hundred pounds. If they’re properly maintained, these aluminum molds can be used for runs in excess of one hundred thousand parts. So, what accounts for the longer life span? The low pressure required for the structural foam molding process minimizes wear and tear on the components. Plus, the ability to design molds with multiple gate points optimizes processing and overall tonnage requirements.
It’s hard to answer such a question without knowing the particular needs of any specific project. However, if your project’s design features certain characteristics, then structural foam may be the right solution for you. If the part is large and needs to maintain high structural integrity, this may be the right way to go.
Structural foam injection molding is good for making parts with an increased stiffness of up to four times other injection molded parts, and it can do this while decreasing the part weight. If the design requires medium-to-thick wall cross-sections, this technique could be a strong candidate for your project. If the goal is to minimize part sinks, structural foam is capable, here, too.
Check out our worksheet, “Which Injection Molding Technology Is Right for You?” to learn more.
If you’re ready to discuss your project details, contact us.
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Part 1 of this blog post discussed some important considerations for custom mold designs for injection molding projects. Topics included the impact of resin selection and mold construction materials. Now, let’s consider how the resin is injected into the mold and the impact of the wall thickness of the part.
The opening through which resin is injected while molds are clamped together is known as the gate.
The gate’s design, location, and type have important effects on the final part, including packing, gate vestige, dimensions, warping, and overall cosmetic appearance.
Two types of gates are used in injection molding: manually trimmed and automatically trimmed.
Manually trimmed gates require an operator to separate parts manually from the runners after each cycle. This type of gate would typically be selected for materials such as PVC that cannot be subjected to high shear rates, or the design requires simultaneous flow distribution across a wide front.
Automatically trimmed gates have a feature built into the mold that shears the part upon ejection. These types of gates are used to eliminate the need for manual shearing, which can help cut costs, maintain a consistent cycle time across all runs, and minimize part scarring.
Your mold’s gate design plays a major role in choosing which gate type to use. The size and shape of the component will dictate which gate designs are available for your application.
A gate’s location on the mold is important because it is crucial to providing the best fill for the application. Gates should be placed at the heaviest cross-section, which allows for proper part packing while reducing voids and sinks. Gates should be located away from cores and pins to reduce obstructions in the path of the flow. If possible, place the gate in an area where stress from the injection will not detract from overall aesthetic requirements or functionality. The gate should also be located to shorten the flow path in order to prevent cosmetic flow markings. With the addition of multiple gates, optimum mold flow can be achieved, but weld lines, also known as knit lines can become an issue. A weld line is created where two flow fronts meet and are not able to meld together. This can have a weakening effect on the part.
Keep in mind that the mold’s gates can vary in both shape and size. This is usually determined by the size and shape of the part. Larger parts require larger gates. Smaller gates provide a better appearance, but they can take longer to mold or require higher pressure for a proper fill.
Wall thickness is among the most important features of your injection molded component. The part’s wall thickness can have a major impact on production quality, speed, and cost of the final parts.
Although there is no ideal wall thickness for injection molding, as a rule, minimizing wall thickness is usually the goal during design to reduce cost and weight. Parts with thinner walls require less material and less time to cool, both of which can greatly reduce cost. Minimizing wall thickness requires taking factors like structural requirements, the specific resin being used, and the part’s size and shape into account.
A constant wall thickness is key to molding high quality parts. Thicker sections take longer to cool than thinner sections. That means thin walls are already cool while the thicker walls are still cooling, which causes them to shrink around the thinner walls. That can cause the component to warp, crack, and twist. If different wall thicknesses are necessary, make the change in thickness gradually; overall differentiation should be no greater than 10 percent. There is a trade-off however. Thin walls will require higher injection pressures and tend to be less forgiving for stresses. An experienced mold designer can help you come up with design alternatives such as using cores and ribbing.
When designing custom molds for your parts, also consider issues like draft, sink marks, textures, and parting lines. The mold draft facilitates removal of the part from the mold. The degree of draft will vary with geometry and other part characteristics including surface texture requirements. In general, the more draft the better. Sink marks occur when the exterior walls cool faster than interior ones, creating warpage or unsightly marks or adding stress to the part. These marks most commonly occur at bosses, corners, and ribs.
Considerations to eliminate sink marks include reducing the thickness of an area by coring it out or making sure bosses and ribs are no more than 60% of the thickness of the nominal wall. Parts can also be molded with a texture in the mold.
Adding textures can provide functionality or improve cosmetic appearance while hiding imperfections such as sink marks and parting lines. Every molded part will have parting lines. Given that the parting line is the easiest place for venting, melted resin will always flow toward it. Consider your application when creating the parting line. A sharp edge at the parting line will it less visible while a safety edge radius is preferable for medical applications or toys.
Keeping these things in mind when designing your custom mold and discussing them with your designers and engineers will help to ensure you achieve the most economical solution for your injection molding process.
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[post_title] => Custom Mold Design: Part 2 [post_excerpt] => Learn more about the components included in your custom mold design. What kinds of questions should your mold engineering and design team be able to answer? [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => custom-mold-design-part-2 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-custom-mold-design-part-2/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [57] => WP_Post Object ( [ID] => 2377 [post_author] => 3 [post_date] => 2019-03-06 19:40:00 [post_date_gmt] => 2019-03-07 00:40:00 [post_content] =>Designing custom molds for your injection molded products can be a complex process. However, working with the right team can greatly reduce the complexity and cost while improving the quality of the completed part and minimizing the length of the production cycle. Take the time to answer the following questions before you attempt to design molds for injection molding.
Aside from determining core function and structural features, the injection molding process itself is a factor to consider. A part’s features must be reviewed carefully in terms of how the resin material enters and fills the mold cavity, as well as how the material cools while in the mold. An experienced tool design engineer understands how to control mold temperature and cooling rate process optimization. This critical step will help to optimize cycle times, reduce stress in the part and prevent various physical and cosmetic defects. The result is a stronger part that is easier to manufacture.
Injection molding has long been the most popular method for manufacturing plastic parts. In fact, at any given moment, you can likely find several products that were injection molded, including the pen you use, your smartphone’s body, bottle caps, many types of plastic containers and housings, car components and interiors, computer keyboards, and so many others. Injection molding is ideal is for high volume production runs. With the right setup and tooling, several components can be produced in a single cycle with high tolerances, low labor costs, and minimal parts finishing. That being said, the single greatest drawback to injection molding is the initial upfront costs for creating custom molds and tooling. That is why getting the mold design right is so important.
Part designers can choose from literally thousands of different resins for an injection molding process. Most of these resins are thermoplastics, but some elastomers are also available. When deciding on which resin to use for a particular part, it’s important to weigh a resin’s flexibility, moldability, strength, and cost; these factors will also have an impact on the choice of mold material. The various metals that can go into a mold offer a variety of temperature handling capabilities and often respond in different ways to various processes. Consider how many parts you will need to manufacture and how often when creating a custom mold design. For example, molds cut from steel last longer and can typically handle more injection molding cycles than an aluminum one, but steel tends to be costlier. Does your project require the strongest materials or will less durable ones suit your needs? How many molds do you need to build at a time? How many do you need running at a time? How many do you need to reserve as backups?
Just as with resins, there’s a wide variety of injection molding machines to choose from - each with its own set of capabilities. They typically all have the same components: a material hopper, an injection ram or screw plunger, and a heating unit. Once molds are clamped to the machine and in the ready position, melted plastic is injected into the mold. Machines are rated by tonnage, which indicates how much clamping force the unit can exert. Machine tonnages typically range from 5 tons to 6,000 tons. Larger parts require higher tonnage machines to exert enough force to spread molten resin quickly through the mold cavity. To determine machine tonnage required, the projected area of the part is multiplied by a clamp force factor ranging from 2 to 8 tons per square inch of the projected area. As a general rule of thumb, a clamp force of 4 or 5 tons per square inch is sufficient for most products. Less flexible materials will require more pressure to fill the mold properly.
A mold, sometimes called a die or tool, represents a major portion of the costs associated with injection molding for most manufacturers because they often pay for designing and manufacturing their own molds, then loan them out to full-service contract manufacturers to carry out the actual injection molding process. Injection molds are usually cut from hardened steel, pre-hardened steel, aluminum, or a beryllium-copper alloy. The choice of material to use for your custom mold typically comes down to what makes the most sense financially. It is important to focus on the long-term cost versus up-front tooling cost. Hardened steel molds are more expensive to produce, but their wear-resistant characteristics allow for longer working lifespans and require less maintenance. Standard tool steels are less expensive, but they usually offer a shorter lifespan and require more maintenance.
Aluminum molds can be significantly less costly than steel molds and are usually intended for lower quantity production parts. Molds made of higher quality aluminum, such as QC-7 and QC-10, can produce hundreds of thousands of parts. Aluminum molds also have another advantage; they offer better heat dissipation properties than steel molds, so cycle times are shorter, allowing for quicker turnarounds. Aluminum molds can also be coated to help them withstand the heat and pressure longer, extending their useful life.
For parts that require higher temperatures than typical injection molded parts or fast heat removal, beryllium-copper molds are the best option.
A variety of molding methods are available for products or molds that demand specific techniques. To make more informed decisions, familiarize yourself with the different approaches to injection molding before finalizing your custom mold design.
Although “reduce your stress” sounds like an invitation to focus on your mantra, in the context of designing custom injection molds, stress reduction refers to a specific engineering technique. Injection molded parts can suffer from stress, which is due in large part to their design. When plastic resins are melted, this causes the bonds between their molecules to weaken and stretch temporarily. As the part cools, those bonds are reestablished and harden. When the plastic is forced through hard turns, various geometric features, and other sharp distortions, the material stretches further, creating a stress point, which is frozen into the part as the resin cools.
Stress in an injection molded part typically results in warpage, cracking, and premature failures, but other effects of part stress can also occur.
Here are some key approaches to minimizing part stress:
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[post_title] => Custom Mold Design: Part 1 [post_excerpt] => Have you considered ALL of the angles with your custom mold design? Is your injection molding manufacturer providing you all of the important details? [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => custom-mold-design-part-1 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-custom-mold-design-part-1/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [58] => WP_Post Object ( [ID] => 2379 [post_author] => 3 [post_date] => 2018-10-24 14:22:00 [post_date_gmt] => 2018-10-24 19:22:00 [post_content] =>
At Ferriot, we realize that many (if not most) savvy medical industry OEMs want to focus on their core competencies and let another company perform the details of the actual product build. Contract Manufacturing provides numerous opportunities to greatly reduce capital expenditures and operating costs while ensuring the highest quality for the final product.
What we’ve learned over our years of experience is that there’s a clear process to follow to guarantee success when using a contract manufacturer. When done correctly, applying the right process results in both great customer satisfaction and great performing products.
For companies considering transitions or moving production to a contract manufacturer, the process is very much the same as when entering any long-term business relationship. It's all about gathering as much information as possible and then making an educated, informed choice.
In the article, Seven Steps to Successful Contract Manufacturing for the Medical Industry, our very own Dave Hartman presents some guidelines that can be used as a road map for a successful partnership between a medical industry OEM and a contract manufacturer including these steps:
To learn more about all seven steps to contract manufacturing success, read the full article in Medical Design Briefs.
Ferriot is a full-service provider of injection molded products ranging from enclosures and encasements for medical equipment to business machines, industrial and consumer products. Our extensive expertise includes engineering, tooling design, injection molding, custom molding, sub- and finished assembly and the on-time delivery of components and finished products for major industry.
Ferriot’s engineering team can design complex molds and develop products with outer surfaces with a varying range of performance requirements necessary in a medical environment. The team takes products and components from concept to finished manufacturing — starting with mold design and engineered resin selection, to finished product production, complete with decorative finishes and branding.
Examples of our medical solutions include:
With almost 90 years of institutional experience, a trained workforce averaging nearly 20 years of experience per employee and a 200,000-square-foot facility, Ferriot runs multiple assembly lines around the clock. Quality-control extends to every product they turn out.
Contact Ferriot to learn more.
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[post_title] => Medical Industry Contract Manufacturing Success featured in Medical Design Briefs [post_excerpt] => The seven steps to successful contract manufacturing in the medical device industry are featured in Medical Design Briefs. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => medical-industry-contract-manufacturing-success-featured-in-medical-design-briefs [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-medical-industry-contract-manufacturing-success-featured-in-medical-design-briefs/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [59] => WP_Post Object ( [ID] => 2381 [post_author] => 3 [post_date] => 2018-09-24 16:28:00 [post_date_gmt] => 2018-09-24 21:28:00 [post_content] =>
We're pleased to announce that Craig Ferriot, President, Ferriot, Inc. will be speaking at the MFG DAY event on October 5th at the Hilton Garden Inn, Akron, OH. Craig's presentation will highlight some of the technological innovations being utilized in the injection molding industry.
"Celebrate Manufacturing Day: Spotlighting Innovation in Northeast Ohio”
Join us for breakfast as we highlight how manufacturers in northeast Ohio are using innovative technology. Dress is business casual.
Manufacturing Day®, a celebration of modern manufacturing, occurs annually on the first Friday in October. Using the theme “Open Doors, Open Minds” the event is meant to inspire the next generation of manufacturers.
For more information on the MFG DAY Event and to register to attend, click here.
[post_title] => Craig Ferriot to speak at MFG Day Event [post_excerpt] => Craig Ferriot, President, Ferriot, Inc. will be speaking at the MFG DAY event on October 5th at the Hilton Garden Inn, Akron, OH. Craig's presentation will highlight some of the technological innovations being utilized in the injection molding industry. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => craig-ferriot-to-speak-at-mfg-day-event [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-craig-ferriot-to-speak-at-mfg-day-event/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [60] => WP_Post Object ( [ID] => 2383 [post_author] => 3 [post_date] => 2018-07-11 12:33:00 [post_date_gmt] => 2018-07-11 17:33:00 [post_content] =>
It’s not every day that your company gets featured in a trade publication! It’s even more unique to be worthy of the cover story! The Ferriot team is proud to share with you our BIG IDEAS as they come to fruition.
Throughout the history of manufacturing it seems that consumer needs often result in innovation, one way or the other.
Here at Ferriot, we’ve been seeing an uptake in demand for adding additional molded-in features to plastic parts—especially larger, injection molded structural foam parts. This is also a much more cost-effective solution for assembly.
Recently, we added a 2,250-ton Negri Bossi Bi-Power, our largest press ever! It took a fleet of five 18-wheelers to deliver. The entire system encompasses a Conair Carousel Plus W400 dehumidifying dryer, a Kuka six-axis robot and a conveyor. We had to take a novel approach by integrating the Sytrama SCP2 control with the Kuka. Our aim in all this was to make programming the robot easier for the technicians.
Clients demand parts that are precise, and with Ferriot’s 20 injection molding presses we are committed to finding them a solution that works. The key with injection molding is how quickly the machine can be changed over from part to part. Downtime costs money and we don’t want to pass those costs on to our clients.
We recently talked about this with Plastics Machinery. You can download the full article here.
Learn more:
[post_title] => Ferriot featured in Plastics Machinery Magazine! [post_excerpt] => At Ferriot, we’ve been seeing an uptake in demand for adding additional molded-in features to plastic parts—especially larger, injection molded structural foam parts. This is also a much more cost-effective solution for assembly. Here's our BIG IDEA... [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => ferriot-featured-in-plastics-machinery-magazine [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-ferriot-featured-in-plastics-machinery-magazine/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [61] => WP_Post Object ( [ID] => 2385 [post_author] => 3 [post_date] => 2018-05-02 17:48:00 [post_date_gmt] => 2018-05-02 22:48:00 [post_content] =>
Design engineers and their employers have shifted focus from the days when their company created an injection-molded part, turned it over to a contract manufacturer, and the purchasing department followed-up on delivery.
For production quality, cost control and innovative solutions, design engineers and their companies now seek vendor-as-partner relationships. The exchange of knowledge between designer/company and vendor creates an inclusive goal set, including part design/optimization, tooling modifications or simplifications, cost containment, just-in-time delivery and special finishes. The result is a vendor who can “fill the gaps” in the company’s capabilities to identify positive, proactive opportunities beyond the customer’s RFQ.
One customer shifted their focus when they needed help in creating parts for a redesign of one of the company’s top sellers.
“We look for vendors with experience in areas of injection molding we need.” The material manager found a vendor that had molded faceplates for ATMs and gasoline pumps which would withstand extreme conditions like temperature changes and chemical exposures. The material manager explained “These products the vendor created were rugged, and even after exposure to the elements, the finish still looked great. Our product would never be in those conditions, but they had the experience to develop quality and durable products for those industries. They certainly have the technology to develop products for us.”
Qualifying multiple vendors for key injection molding is standard. The first reason for having a contingency plan is obvious: preparing in the event of unexpected major equipment failure, fire, work stoppage or other disaster.
A second qualifying practice makes good economic sense. This customer screens alternative suppliers for comparative price checks. Customer finds “Price protection is a thing of the past; every price is subject to change based on every little market whim. Without market index pricing with a particular vendor, I need to confirm pricing, and I do that with a second vendor source. If one vendor claims a price increase, I want to see that market adjustment with all my sources.” The customer is reasonably wary about price increases, “Sometimes, frequent price increases may indicate a vendor’s processes are faulty, creating too much scrap, for example.”
For this customer, they were able to identify their critical characteristics for an injection molding partner:
Keep reading this case study that shows the company’s selection process in finding that responsive, reliable and innovative vendor partner. Download the entire study, to learn more about the targeted questions they asked of vendors, and how they found and developed the vendor-as-partner relationship to support their direct injection-molding needs. Find best practices in evaluating direct injection molding vendors you can apply today.
[post_title] => Case Study: How to turn an Injection Molding Vendor into a Partner [post_excerpt] => Learn how to turn an Injection Molding Vendor into a full-service Contract Manufacturing Partner from industry experts at Ferriot. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => how-to-turn-an-injection-molding-vendor-into-a-partner [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:15 [post_modified_gmt] => 2024-03-11 20:11:15 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-how-to-turn-an-injection-molding-vendor-into-a-partner/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [62] => WP_Post Object ( [ID] => 2387 [post_author] => 3 [post_date] => 2018-04-17 14:20:00 [post_date_gmt] => 2018-04-17 19:20:00 [post_content] =>
Akron, Ohio, April 17, 2018: Ferriot Inc., a custom injection molding company and contract manufacturer has appointed two new members to its quality team. Richard Hodnick has been appointed to Director of Quality and Joe Steger as Quality Engineer.
Rich has 30 years of experience leading both public and private companies in the areas of quality assurance, process engineering, reliability engineering and project management. Rich and his team of quality improvement engineers and technicians will be charged with advancing both our capabilities and increasing responsiveness and satisfaction levels with our customers.
Rich’s initial goals are registration of Quality Management Systems (QMS) for Ferriot and wholly owned subsidiary, American Original Building Products LLC, to the new ISO 9001:2015 quality standards. In addition, he will focus on fully integrating the QMS into the IQMS ERP system allowing the company to fully realize the benefits of this closed loop business system.
Quality Engineer, Joe Steger, has served in several significant quality and manufacturing roles that include 13 years as Quality Assurance & Reliability Lead Engineer and 10-years of experience as a CNC machinist and molding/tooling/finished good inspector. Recent accomplishments for Joe include co-developing and implementing a reliability testing laboratory. He looks forward to getting know Ferriot’s valued customers and becoming familiar with IQMS.
Craig Ferriot, President of Ferriot, Inc. said, “Both are great additions to our team and understand the importance of customer satisfaction.”
Ferriot, Inc. is a full-service contract manufacturer and custom injection molder of engineered resins. Privately held since its founding in 1929, Ferriot employs veteran engineers and skilled technicians of the manufacturing and plastic injection molding industry. Ferriot’s contract manufacturing services include engineering, design, molding, sub- and final assembly, delivery of components and finished products for a variety of industries. Markets include building and construction, medical, industrial, business machines, oil and gas, electronics, consumer goods and more.
[post_title] => Growing Injection Molder/Contract Manufacturer Focuses on Quality for Long-Term Success [post_excerpt] => Richard Hodnick has been appointed to Director of Quality and Joe Steger as Quality Engineer. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => growing-injection-molder-contract-manufacturer-focuses-on-quality-for-long-term-success [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:15 [post_modified_gmt] => 2024-03-11 20:11:15 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-growing-injection-molder-contract-manufacturer-focuses-on-quality-for-long-term-success/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [63] => WP_Post Object ( [ID] => 2390 [post_author] => 3 [post_date] => 2018-04-12 14:15:00 [post_date_gmt] => 2018-04-12 19:15:00 [post_content] =>Structural foam molding has become a highly evolved technique. Today, thermoplastic resin can be mixed with a chemical blowing agent to expand the melted resin and produce high-strength parts for use in industrial applications. The thermoplastic microcellular structure weighs 10% to 30% less and is stronger and more resilient than traditional injection molded parts.
The Brave New World of Structural Foam Molding
Modern structural foam molding vs injection molding differs significantly. “Structural foam” describes the result of the blend of thermoplastic resin and blowing agent when activated by heat. The blowing agent creates a foamed microcellular structure that fits itself into the form of the mold.
Structural foam molding can be conducted at lower pressures than injection molding creating less stress on the formed parts and therefore, less warping. This low-pressure technique also allows for the use of much less expensive tools. Long-lasting molds can be made of aluminum rather than tool steel. Structural foam molded parts are stronger and lighter than parts created with traditional injection molding techniques because they aren’t as dense.
Structural Foam Parts Are Lighter and Stronger
Structural foam parts have much higher strength-to-weight and strength-to-stiffness ratios than injection molded parts. They are also much more impact resistant due to the microcellular structure.
When parts need to be scaled up in size, structural foam molding is the optimal strategy. Structural foam molding can be used to create small parts or much larger, complex parts without sacrificing the speed that would be required to injection mold larger parts.
As an additional benefit, structural foam molded parts have zero sink marks. Sink marks resulting from injection molding and can leave a rough, unsightly surface that is difficult to clean. Structural foam molding leaves a smooth external surface that is easily cleaned and can even be painted if desired.
Ferriot: Structural Foam Molding Specialists, and Just Good People
Ferriot has developed an in-depth understanding of the vast new set of strategies behind structural foam molding processes. Ferriot now operates a high-quality in-plant structural foam molding system. Many Ferriot customers are so confident in the quality of Ferriot’s foam molded parts that they are shipped directly to end users.
As an additional benefit, Ferriot is a quality-oriented, engineering-oriented organization that strives to do things right the first time. They understand that product quality and delivery, and vendor reliability are crucial in today’s markets.
Among Ferriot’s customers, many deeply appreciate the company’s willingness to handle short runs with high levels of process automation. Ferriot’s superior shop-floor documentation and process control often attract new customers and keep existing customers coming back.
One such customer is ILC Dover. You can read the full case study here.
[post_title] => Foam Molding Produces Lighter, Stronger Parts at Lower Cost [post_excerpt] => Ferriot has developed an in-depth understanding of the vast new set of strategies behind structural foam molding processes. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => structural-foam-molding-process-produces-lighter-stronger-parts-at-lower-cost [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:15 [post_modified_gmt] => 2024-03-11 20:11:15 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-structural-foam-molding-process-produces-lighter-stronger-parts-at-lower-cost/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [64] => WP_Post Object ( [ID] => 2392 [post_author] => 3 [post_date] => 2018-03-28 17:16:00 [post_date_gmt] => 2018-03-28 22:16:00 [post_content] =>Many medical device original equipment manufacturers (OEMs) work with a contract manufacturer on the fabrication and assembly of products for new product designs, especially when the parts need to be precisely machined or cast. In the case of parts made from engineered resins, it is essential that OEMs of medical devices find contract manufacturers (CMs) that do excellent, precise work the first time, every time.
Meeting of the MindsWhile a part may be conceived and designed, it is still important for the OEM to choose a CM that has extensive experience manufacturing medical devices and is a good fit culturally. The CM must have the knowledge, equipment and resources to produce medical components with the accuracy and in the numbers that the OEM requires. For the two companies to share a corporate culture and an overall approach to work can also be beneficial in terms of the ensuing business relationship.
The collaborative process is much easier if the manufacture of an existing product is being transferred, all work instructions and current sources should be shared with the new CM. If a new component is being manufactured or a new product being launched, the CM may well be responsible for developing the assembly flow and the work instructions for the build.
Starting from Scratch
In an alternative scenario, if sources for components must be identified and inspected, a different sort activity begins. The entire development, qualification, and supply line management for components must be developed. Ferriot specializes in this type of relationship. This requires an experienced team who are familiar with the medical industries, with the processes and standards particular to medical injection molding, such as cleanliness standards, lot number traceability, medical drying procedures and superior tight tolerance precision molding.
Design Accuracy
When an OEM is working with a CM, there are a number of steps that can be taken to ensure that a medical device or medical device component is produced precisely and exactly as required on the first run and on every subsequent run. The accuracy of the process begins at the beginning; It starts with a clearly defined product.
The design and specification of any medical-related products must be performed in a very accurate and precise manner. The use of computer aided design (CAD) for medical devices or components is essential in the early stages. The plans created using CAD programs are themselves very detailed and accurate and this can help in the production of accurate components.
Production
Once the flow, work instructions, and components are all in place, operator training and qualification starts. Pilot builds are conducted and comprehensive qualification of the finished product or sub-assembly is the last major effort in preparation for production. This should be carried out by the medical inventor of the product and/or a medical professional with knowledge of medical device production.
As the production phase is entered, having a good plan drives procurement, production and inventory. Having a realistic forecast upon which to build the production plan is very important. When it’s done well, the process will provide great customer satisfaction and great final product.
A Good Contract Manufacturer
There are numerous aspects to manage, when an OEM is participating in a new production program. A good CM will allow the OEM to remain focused on their core competency and intellectual property.
When the CM is truly serving the needs of an OEM, the OEM can spend less capital, hire fewer laborers, spend less time on quality control, worry less about purchasing and know that someone else is ensuring the technical skills of the people involved. The OEM can also control inventories at manageable levels, without being required to focus on details.
Perhaps most important, working with a quality CM offers a single point of contact for everything an OEM might need. There is no more worrying about whether all of the production partners will be able to supply the required components. A good CM takes care of these concerns well in advance.
At Ferriot, we know that manufacturing is complex, but we don’t think it should be more complicated for you than it needs to be. We think of contract manufacturing as a partnership. Like any good partnership, that means we work hard to ensure you get what you need at high quality, on time and on budget.
Learn more about the 7 Steps to Successful Contract Manufacturing for the Medical Industry.
[post_title] => Steps to Building an Optimal Relationship between a Medical Device OEM and a Contract Manufacturer [post_excerpt] => Many medical device original equipment manufacturers (OEMs) work with a contract manufacturer on the fabrication and assembly of products for new product designs, especially when the parts need to be precisely machined or cast. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => steps-to-building-an-optimal-relationship-between-a-medical-device-oem-and-a-contract-manufacturer [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:15 [post_modified_gmt] => 2024-03-11 20:11:15 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-steps-to-building-an-optimal-relationship-between-a-medical-device-oem-and-a-contract-manufacturer/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [65] => WP_Post Object ( [ID] => 2395 [post_author] => 3 [post_date] => 2018-03-12 14:11:00 [post_date_gmt] => 2018-03-12 19:11:00 [post_content] =>Manufacturing plant engineering Green Energy with new air-cooled compressor
Akron, Ohio – March 12, 2018 – Ferriot, Incorporated, an injection molding and contract manufacturing company, is installing a new heat recovery system to improve the facility’s energy efficiency and lower operating costs.
Ferriot operates a 200,000-square foot facility in Akron, Ohio. Running the machinery and heating a facility of that size requires a lot of energy. To conserve energy while growing the business, Ferriot’s new heat recovery system will re-use waste heat for space heating. The term “heat recovery” describes the collection and re-use of heat arising from any process that would otherwise be lost.
For many businesses, including Ferriot, heating and cooling is one of the more significant operating costs. A typical office building in the northern U.S. can spend nearly 40 percent of its energy cost on heating. Most businesses use another six percent of its energy usage on heating water. For many industries, especially manufacturing, heating demands are even higher. Steam and process heating can account for more energy use than space heating.
In Ferriot’s case, waste heat recovery will come from the air compressor that powers all of its machines. The company will be moving from a water-cooled compressor to an air-cooled compressor when it installs a new 125 HP Sullair Air Compressor. The Sullair compressor has a variable frequency drive, allowing it to only run when needed. It will also reduce the load on the water tower by cooling with air instead of water.
“This new air-cooled compressor system will allow Ferriot to realize an energy savings between 10 and 15 percent,” said company President Craig Ferriot. “The greatest energy savings will be realized in cooler months. More than 90 percent of energy input to a compressor is lost as heat when the air is extracted and dumped into the environment. Reducing energy consumption occurs when this heat is captured for use elsewhere.”
The Sullair Air Compressor heat exchanger will be connected to ductwork. The warm air generated by running the compressor will be blown back into the plant to heat the space – a process that is becoming more common in manufacturing. The heat energy is passed into the production space. This will enable Ferriot to shut down two air handling units that provide comfort heat in certain areas of the plant. A more powerful air compressor and less draw on water for cooling purposes, will also provide additional capacity for cooling the new presses and other equipment.
This state of the art compressor has other benefits including a 10-inch screen display with a computer and mobile phone connection allowing for remote monitoring.
About Ferriot Inc.
Based in Akron, Ohio, Ferriot is a full-service contract manufacturer and molder of engineered resins that provides specialized engineering assistance, complex thermoplastic material development, injection molding, painting and decorating, contract manufacturing, and commitment to total quality management. Ferriot provides these services throughout the United States to customers in the following markets/applications: Business Machines, Building Products, Industrial, Medical Devices, Electronics, Bio-Tech, Energy Management, Oil and Gas, Water Management and Tier 2 Automotive. To learn more, visit www.ferriot.com.
[post_title] => 10 Critical Questions to Ask Before Starting an Injection Molded Project
[post_excerpt] => We’ve narrowed it down to 10 critical questions you should ask before beginning any injection molding project.
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[post_content] => As we mentioned in our blog last week, Ferriot is in the process of installing a new 2,250-ton Negri Bossi Bi-Power injection molding press. We were very excited to see this announcement featured in Plastic News and are both thrilled and a little humbled by the mention.
Ferriot is investing more than $1 million in the new press that will enable us to increase our production capabilities and address the on-time delivery needs of our growing customer base. The full installation will also be documented via Go Pro and the installation progress will be shared on our website.
Craig Ferriot, our company President said, “one of Ferriot’s niches is large, high-pressure structural foam medical and business machine housing that require high cosmetic finishes, which is one of the target markets for this press.”
Ferriot Inc. is honored to be mentioned in Plastic News. We’re excited for all to watch the progress of this installation. This is our first time documenting an installation for all to see.
You can read the full article from Plastic News by clicking here, Ferriot putting more than $1 million into equipment, infrastructure.
To read our blog detailing the progress updates click here, Progress Updates on New Negri Bossi BI‑POWER Injection Molding Press Installation
To continue to follow up on the latest press installments, subscribe to our email list.
[post_title] => Plastic News Features Ferriot’s Latest Injection Molding Press Install [post_excerpt] => As we mentioned in our blog last week, Ferriot’s latest installing of a new 2,250-ton Negri Bossi Bi-Power injection molding press. We were very excited to see this announcement featured in Plastic News and are both thrilled and a little humbled by the mention. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => plastic-news-features-ferriots-latest-injection-molding-press-install [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-plastic-news-features-ferriots-latest-injection-molding-press-install/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [68] => WP_Post Object ( [ID] => 2402 [post_author] => 3 [post_date] => 2018-01-25 15:06:00 [post_date_gmt] => 2018-01-25 20:06:00 [post_content] =>
Once installed, the Negri Bossi injection molding press, six-axis robot and auxiliary equipment will take up a 25-by-60-foot area on the shop floor. The company is providing updates on the installation via a GoPro camera.
Ferriot Inc. is investing more than $1 million in a project that includes the installation of a new 2,250-ton Negri Bossi Bi-Power injection molding press, six-axis robot, auxiliary equipment and infrastructure improvements.
Craig Ferriot, president of the Akron, Ohio-based custom injection molder and contract manufacturer, said business is increasing, especially for larger parts, including cosmetic enclosures for markets such as business machines, electronics, medical devices, industrial components and consumer products.
"One of Ferriot's niches is large, high-pressure structural foam medical and business machine housings that require high cosmetic finishes, which is one of the target markets for this press," he said in an email interview.
The new press will come equipped with a wireless Amico system for remote monitoring in addition to an IQMS ERP system that Ferriot installed and implemented across all of its presses in 2015. Press connectivity and industry 4.0 upgrades enable better reporting to improve processes and efficiencies, Ferriot said.
"IQMS connects our machines to our enterprise system, allowing process monitoring in real time," he added. "This gives visibility of production status and traceability to customer orders."
The 2,250-ton Negri Bossi will be Ferriot's largest machine yet — presses at the company start at clamping forces of 42 tons — and the company's first time documenting the installation for all to see.
To do so, Ferriot has installed a GoPro camera on the ceiling of the production area where the new press will be assembled. Each week, the company will provide photo updates online and will eventually release a time-lapse video of the full installation.
"By using time-lapse photography, we want to show what it takes to install a piece of equipment like this and, in the end, will produce a video that shows the process from start to finish," Ferriot said.
So far, the concrete foundation has been poured and cured, and the infrastructure has been put in place. Arrival of the press and auxiliary equipment, which will be delivered on five semitruck loads, was delayed three weeks due to weather at the port and a standstill at U.S. Customs and Border Protection. Ferriot expects the first truck to reach the facility the week of Jan. 29.
The press should be fully operational and producing the first orders for customers by mid March, he added.
"We intend to continue investing in technology and retire old assets," Ferriot said in a follow-up phone interview. "We're seeing most of the opportunities right now in machinery that is 500 tons and up."
With the addition of the new Negri Bossi press, Ferriot will have 20 injection molding machines at its 200,000-square-foot facility. The company has roughly 130 employees after increasing its workforce by about 15 percent over the last year, Ferriot said.
Ferriot ranks No. 186 in the annual survey of injection molders by Plastics News, with estimated sales of $30 million.
[post_title] => Ferriot Putting More Than $1 Million Into Equipment, Infrastructure [post_excerpt] => Ferriot Inc. is investing in a new 2,250-ton Negri Bossi Bi-Power injection molding press, six-axis robot, auxiliary equipment and infrastructure improvements. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => ferriot-putting-more-than-1-million-into-equipment-infrastructure [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-ferriot-putting-more-than-1-million-into-equipment-infrastructure/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [69] => WP_Post Object ( [ID] => 2404 [post_author] => 3 [post_date] => 2018-01-24 19:39:00 [post_date_gmt] => 2018-01-25 00:39:00 [post_content] =>As anyone who’s worked in construction can tell you, nothing draws a crowd of “sidewalk superintendents” quite like the sight of someone else hard at work. Now, you can join the crowd without ever leaving your desk. Ferriot has installed a Go Pro camera on the ceiling in the production area, above the area where we’re assembling our new 2,250-ton Negri Bossi BI‑POWER injection molding press. Each week, Ferriot will update the photographs to allow checking in on the progress of the installation. In addition to using these photographs for sales and marketing purposes, the camera will let us document this milestone in our company history with a time-lapse video. To check on project status, visit our Negri Bossi Press Installation Progress page.
I’m happy to report the installation is proceeding on schedule (more or less), with the site preparation and floor reinforcement phases now complete. The concrete foundation we poured at the end of November has cured and the massive components of the press (one of which weighs 70 tons!) and its peripherals will be delivered on five semi-truck loads. Due to an unusually cold winter, the components must be inside our building for a few days and must reach room temperature before installation can begin. Installation should be completed by late February.
The press configuration we chose is designed to support producing the largest plastic parts we’ve ever handled. Once it’s installed, the press will allow us to boost production capacity, operate more efficiently, and reduce delivery times to our customers. The installation of the press is part of our long-term plant reconfiguration effort designed to use floor space more efficiently, boost labor productivity, simplify movement and the flow of work through the facility, and ease supervision.
The new press will have an integrated Columbia industrial PC and a variable delivery pump hydraulic system that allows for precise process control and high power efficiency. The support team at Negri Bossi will be able to monitor its operation remotely via the Internet at any time so they can perform diagnostics, troubleshooting, and intervention in real time.
We invite you to stop by the Negri Bossi press installation page to check out our progress. You can also follow us on LinkedIn, Facebook and Twitter.
If you want an overview of how a press of this type comes together, why not take a few minutes to watch a YouTube video that shows one of Negri Bossi’s larger Bi-Power presses being assembled? It’s available at https://youtu.be/bEmbwcb3oWs.
Interesting in hearing more or want notified when new blogs are released? Subscribe to our blog so you never miss an update.
[post_title] => Progress Updates on New Negri Bossi BI‑POWER Injection Molding Press Installation [post_excerpt] => Ferriot has installed a Go Pro camera on the ceiling in the production area, above the area where we’re assembling our new 2,250-ton Negri Bossi BI POWER injection molding press. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => progress-updates-on-new-negri-bossi-bi-power-injection-molding-press-installation [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-progress-updates-on-new-negri-bossi-bi-power-injection-molding-press-installation/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [70] => WP_Post Object ( [ID] => 2413 [post_author] => 3 [post_date] => 2017-12-19 15:02:00 [post_date_gmt] => 2017-12-19 20:02:00 [post_content] =>New press to increase production capacity, speed customer service significantly
Akron, Ohio – December 19, 2017 – Buyers of oversized injection molded plastic parts will have another potential supplier in 2018. The site preparation and floor reinforcement process for a new 2,250-ton Negri Bossi BI-POWER injection molding press has already begun at the Ferriot, Incorporated production facility on Arlington Circle in Akron, Ohio. The press, which will be installed after the New Year, will be the largest in Ferriot’s core business “fleet.”
Company President Craig Ferriot noted, “We invested in the 2,250-ton press to increase our production capacity, operate more efficiently, and accelerate our delivery times for finished products. This new press will also serve as a back-up to our next-largest press, so our customers for larger plastic parts can be confident we’ll always have the capacity to turn around their orders quickly.”
He continued, “Assembling the press and all its peripheral devices—robots, dryers, conveyors and magnetic platens—will involve plenty of steps. To document this process and allow our employees and interested customers to follow along, we’ll be installing a camera that will take periodic time-lapse photographs of the assembly process.”
The Negri Bossi BI-POWER VH2000-22500 press features an integrated Columbia industrial PC and a variable delivery pump hydraulic system designed to deliver precise process control and high power efficiency. A wireless Amico™ system will enable remote monitoring of the press around the clock, which will allow the press’s manufacturer to perform remote diagnostics, troubleshooting, and intervention in real time via the Internet, ensuring greater uptime performance. Ferriot’s press will be paired with a new KUKA multi-function robot and IQMS enterprise systems to provide numerous automation capabilities.
The installation of the press is part of Ferriot’s long-term plant reconfiguration effort designed to use floor space more efficiently, boost labor productivity, simplify movement and the flow of work through the facility, and ease supervision.
Follow the installation progress here.
About Ferriot Inc.
Based in Akron, Ohio, Ferriot is a full-service contract manufacturer and molder of engineered resins that provides specialized engineering assistance, complex thermoplastic material development, injection molding, painting and decorating, contract manufacturing, and commitment to total quality management. Ferriot provides these services throughout the United States to customers in the following markets/applications: Business Machines, Building Products, Industrial, Medical Devices, Electronics, Bio-Tech, Energy Management, Oil and Gas, Water Management and Tier 2 Automotive. To learn more, visit www.ferriot.com.
Akron, OH – October 12, 2017: The engineering website MachineDesign recently featured an article cowritten by Ferriot’s Dave Perkowski and Dave Swigeart, “The Design Engineer’s Checklist for Injection Molding.” Based on Ferriot’s decades of experience as an injection molder, it highlights the importance of resin selection, process choices and design specs when designing and executing any injection molding project.
As any seasoned engineer knows, the design stage is crucial for ensuring that the part will achieve its full potential in its intended application, and careful planning helps to eliminate cost and time overruns during the process.
The article outlines the steps that any design engineer should take before diving into their injection molding project. For example, the first step in designing any injection molded part is answering some basic questions:
The checklist features other considerations that should be shared between the engineer/designer and injection molder and is available for free here. For more information on Ferriot and its injection molding and other contract manufacturing services, visit www.ferriot.com.
Ferriot Inc. is a full-service contract manufacturer and injection molder of engineered resins. Privately held since its founding in 1929, Ferriot employs veteran engineers and skilled technicians of the manufacturing and plastic injection molding industry. Ferriot’s contract manufacturing services include engineering, design, molding, sub- and finished assembly and delivery of components and finished products for a variety of industries including building and construction, medical, industrial, business machines, oil and gas, electronics and more.
[post_title] => MachineDesign Publishes Ferriot’s Molding Checklist For Design Engineers [post_excerpt] => The article outlines the steps that any design engineer should take before diving into their injection molding project. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => machinedesign-publishes-ferriots-molding-checklist-for-design-engineers [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-machinedesign-publishes-ferriots-molding-checklist-for-design-engineers/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [72] => WP_Post Object ( [ID] => 2415 [post_author] => 3 [post_date] => 2017-10-09 20:13:00 [post_date_gmt] => 2017-10-10 01:13:00 [post_content] =>The recognized industry journal Machine Design just profiled Ferriot’s injection molding checklist in a recent article published on its website.
Design engineers know that planning is the most important step when it comes to any process, and injection molding is no exception. Working with an injection molder gives you the advantage of being able to focus on key design decisions rather than the in and outs of the molding process. Before diving in to the production stage, though, there are key considerations that you and your injection molder should agree on to avoid cost and time overruns.
A great first step is clearly defining project overview considerations. You should be aligned on key questions such as:
Making sure you and your injection molder are on the same page in terms of project goals and priorities ensures a smoother process from start to finish, eliminating costly changes midstream or even after production.
Next, you’ll want to agree upon the molding technologies to suit your application. From traditional injection molding to gas-assisted injection molding, each method has its own benefits unique to the application. Clearly outlining the objectives will help make the selection of the technology much easier and effective in the long run.
From material selection, to overall cost, to the product’s intended lifecycle, there are a host of considerations that should be on your injection molding checklist before you start the production process. To learn how to best tackle injection molded parts development, read our entire checklist and more in our Design Engineering Injection Molding Handbook.
[post_title] => The Design Engineer’s Checklist for Injection Molding [post_excerpt] => Tips and tricks for design engineers before choosing an injection molder. Learn about key design considerations to avoid cost and time overruns. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => the-design-engineers-checklist-for-injection-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-the-design-engineers-checklist-for-injection-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [73] => WP_Post Object ( [ID] => 2417 [post_author] => 3 [post_date] => 2017-08-15 18:22:00 [post_date_gmt] => 2017-08-15 23:22:00 [post_content] =>We were pleased to participate in the Industrial Design & Engineering show this past May in Cleveland, Ohio. This show brought together design engineers and plant managers from across the country to learn about emerging technologies and to share their experiences.
Ferriot’s Dave Harman describes a successful Metal-to-Plastic Case History example to show attendees at the Industrial Design & Engineering Show. Picture Courtesy of Machine Design.
During this year’s show, Ferriot was one of five companies participating in the Case Study Corner, where each firm shared details on how they helped a customer. We chose to refer to recent project that involved helping a customer switch from metal to plastic components in their product. It was a very successful strategy for both Ferriot and our customer that not only helped them reduce costs, but also increased the longevity of their components with a more durable plastic part. This particular customer produces the gas station pump housings we all see. Since this part is visible to the consumer, it had to perform well, be cost-efficient to manufacture, and look great to the consumer as well. Ferriot used a lot of our resin selection expertise to recommend a resin that would be chemical resistant, support a high gloss consumer polish and not crack in either hot or cold temperatures.
We’d like to thank Machine Design magazine, one of the show sponsors, for writing about our participation in its blog article. I’d encourage you to read the article to learn about the other four companies that participated in the Case Study Corner, and read our Case History to learn more about the application.
Perhaps, But It’s Worth a Look To Get the Structural Integrity of Metal or Wood, with Lower Weight and Production Costs
If you’re considering a switch to plastic from metal, wood, concrete, fiberglass or other traditional material, structural foam injection molding may be just the process for you.
Structural foam molding is an injection molding process whose injection stage is basically the same as traditional injection molding, but the packing stage is augmented by a chemical blowing agent mixed with the thermoplastic material to create thermoplastic foam. That chemical blowing agent is triggered by heat and expands the material by creating a microcellular structure to form the part against the mold.
The advantages of converting to structural foam injection molded plastics are just as varied as the many products that can be made successfully by this process. They include higher stiffness-to-weight ratios (parts made with structural foam molding can weigh 10 to 30 percent less than other parts, while retaining durability), lower material costs, lower tooling costs, smoother finished part surfaces for easy painting and cleaning, and a wide range of design flexibility.
Some common – and uncommon – products that have been successfully converted from traditional materials to structural foam injection molded parts include palettes for industrial and consumer use, a variety of lawn and garden equipment and supplies, car and truck door handles, sump pump tanks, surgical equipment and even more recently things like voting machine housing, screws and bolts, and even some concept vehicles.
Switching to structural foam injection molding can save costs at many steps along the way to your finished part. For example:
If you’re thinking about converting to a lower weight yet high-strength part to save on production time and costs, structural foam molding may just be the right design choice. When you’ve made the decision to switch, it’s important to share as much detail as possible about your project with your injection molding contractor up front.
Some questions that you and your injection molding partner can answer together include:
At Ferriot we actually recommend developing a project checklist that is shared between the designer, OEM and injection molding partner and referenced often to ensure understanding on the part of all stakeholders. In the end, all involved will appreciate the detail and heavy lifting up-front.
To read more about how to optimize your structural foam and other injection molded parts development process, download our free guideline, “Designing Injection Molded Parts: A Handbook for Designers & Engineers.” Or, if you prefer, call us at (330) 786-3000 for immediate attention.
Learn More:
[post_title] => Structural Foam Injection Molding: A Miracle Process? [post_excerpt] => If you’re considering a switch to plastic from metal or other traditional material, structural foam injection molding may be just the process for you. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => structural-foam-injection-molding-a-miracle-process [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:17 [post_modified_gmt] => 2024-03-11 20:11:17 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-structural-foam-injection-molding-a-miracle-process/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [75] => WP_Post Object ( [ID] => 2423 [post_author] => 3 [post_date] => 2017-05-30 14:00:00 [post_date_gmt] => 2017-05-30 19:00:00 [post_content] =>
How selecting the right design specs, resin and molding process can answer them
Injection molding is a highly-engineered process, and demand for it only continues to grow as more manufacturers replace traditional materials like wood, steel and fiberglass with thermoplastic resins that are lighter in weight but just as durable. Applications and uses for injection molded parts are numerous and expanding, with increased use in the medical, automotive, industrial, housewares, electronics industries, to name a few.
If you’re thinking about a conversion to resin injection molding, you may have questions about the quality of the finished part, what specs to design to, or what process is right for your application. Here are three common questions to ask that can help put your project on the right track from the beginning.
What specs do I design toward?
For most of our projects, they come down to understanding impact resistance on your part, heat exposure and color.
Impact Resistance
At Ferriot, once we know why impact resistance is important and the type of expected impact load (e.g., a fall onto a hard surface from 5 feet, or having loads dropped on it, etc.), our “upfront” impact testing offers valuable insights. By using molds that are similar to the final part, we can produce prototype parts using an array of resins, and then compare their impact resistance. We also conduct Notched Izod tests to measure impact performance expressed in energy lost per unit of thickness at the notch, based on ASTM D256 standards.
Heat Exposure
Your injection molding partner should also pre-test to determine the Heat Deflection Temperature (HDT), the temperature at which a plastic sample deforms under a specified load. The tests should reveal the maximum temperature the part can withstand without deformation.
Other heat exposure-related issues to consider for your part include knowing the type of heat source the part would be exposed to, i.e. a flame, sun exposure or heating element. You and your injection molder can also avoid heat exposure issues by knowing whether the part will be subject to interference with other materials. For example, dissimilar materials have considerable thermal expansions or contractions and may cause an interference condition.
Color Accuracy
The good thing about injection molded thermoplastic parts is the ability to ensure consistent color throughout the part with the right pigment to resin ratio. The problem can arise when trying to match a prescribed color standard. Even with the standard met, you could face the issue of color retention through UV, light and thermal exposure.
At Ferriot, we will test a number of pigment-resin formulas to make sure the resulting color matches your brand identity guidelines.
What resin is the right choice for my application?
Speaking of resins…the right choice of thermoplastic resin can alleviate many issues associated with impact resistance, heat exposure and color accuracy of injection molded parts.
Thermoplastic resins come in two basic classes: engineering grade resins and commodity resins. Here are a few resin types that meet impact, heat and color requirements.
Engineering Grades
Commodities Grades
Process matters: Which injection molding technology can overcome common issues?
With a few exceptions, Ferriot can accommodate almost any thermoplastic resin and nearly any design specifications.
Depending on your part’s requirements, traditional injection molding, structural foam injection molding, gas-assisted injection molding or overmolding – all processes available at Ferriot – will suit a wide range of applications.
The answers to those three questions involve a lot of complexity that you’ll want to discuss more with your contract manufacturing partner. We’ve compiled some additional questions to ask, along with a variety of checklists, to help with your injection molding journey. To read more about how to optimize the injection molded parts development process, download our free guideline, “Designing Injection Molded Parts: A Handbook for Designers & Engineers.” Or, if you prefer, call us at (330) 786-3000 for immediate attention.
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We get it: some people are just not “list” people. But when it comes to a successful injection molding project, getting down to as much detail as possible is the best way to ensure a project’s success.
Applications and uses for injection molded parts are numerous 
and growing, with increased demand from the medical, automotive, industrial, housewares, electronics and many more industries. As such, more product designers, engineers and Original Equipment Manufacturers (OEMs) are inquiring about switching some parts or entire products to injection molded plastics.
Before meeting with an injection molder to discuss a project, completing a checklist will answer many questions up front, and help the process run smoothly from start to finished product. It may seem basic, but at Ferriot we actually work with customers through a checklist to help accelerate communication and collaboration – and eliminate costly late-stage problems and changes that can happen without clear project scope up front.
Here are a few broad project categories for your Injection Molding checklist, and some key questions that fall under each.
Project Overview
Design Specifications
Physical Attributes and Appearance
Project Cost and Delivery
We Don’t Mind the Heavy Lifting Up Front
At Ferriot, we appreciate the thought and questions that go into an injection molding project. The more factors to consider, the better: that way all project stakeholders are clear on expectations. In short – don’t be afraid to make that list!
Of course, the above questions are a sampling of common issues and questions to arise in most injection molding projects. To read more items that should be on your checklist and learn how to optimize the injection molded parts development process, download our free guideline, “Designing Injection Molded Parts: A Handbook for Designers & Engineers.” Or, if you prefer, call us at (330) 786-3000 for immediate attention.
[post_title] => An Injection Molding Checklist Gets All Involved On the Same Page [post_excerpt] => An Injection Molding Checklist Gets All Involved On the Same Page [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => traps-when-selecting-molding-resin-0 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:17 [post_modified_gmt] => 2024-03-11 20:11:17 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-traps-when-selecting-molding-resin-0/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [77] => WP_Post Object ( [ID] => 2427 [post_author] => 3 [post_date] => 2017-05-17 20:36:00 [post_date_gmt] => 2017-05-18 01:36:00 [post_content] =>
Resin selection can be a tricky business. On top of balancing cost, performance, function and moldability to figure out
the right resin for the job, it’s necessary to think how the part will be cleaned and if it will touch food or be used in a sterile medical environment. It’s easy to get overwhelmed and fall into a few traps. We’re here to share our experience to help you to avoid them.
Trap 1: Not Sharing Finished Products Details Early Enough
Share more information with your contract manufacturer than you think is necessary and do it as soon as you form your partnership. What often happens is the process has already begun when designers mention casually that they are stressed out about their customer’s upcoming test procedure on the part. That designer might quickly find themselves going over budget and missing their deadline because the test wasn’t taken into consideration in the resin selection process and it’s back to the drawing board. Overcommunicate with your manufacturer. Having too much information doesn’t exist in this business. By sharing everything you know about the final product usage and testing requirements, you increase your chances of a successful production.
Trap 2: Rushing the Process
We understand. You don’t want your production line sitting idle. You’re excited about being able to see your vision come to fruition and hold the part in your hands. But if you let those considerations take precedence over taking the time to go through the resin selection process properly, you may find yourself with parts that get rejected or worst of all, an end-product recall. Take a breath. A few extra hours or days in upfront planning and communication will be worth it when your project is a success.
Trap 3: Not Pressing Pause When It’s Not Going Well
You’ve engaged a contract manufacturer. When you first started talking to them, they were quick to say they could do the job. They didn’t ask a lot of questions. They seemed hyper-focused on the part itself, not necessarily how it would be used, how it would be cleaned, or how it would be tested. At first, you may take this as a sign of confidence, but warning bells should be going off in your head. Step back and press pause. After all of the strategizing, planning, designing, meetings and everything else that went into your process thus far, you need to evaluate whether this is the right partner for you.
Now that you’ve learned three traps not to fall into, you’ll want to download our white paper that includes more details on these three traps, five tips to help ensure your project is a success, and a high-level attribute list of the features of the most common engineering grade resins and commodities grades. The white paper “The Tips, Tricks, And Traps of Injection Molding Resin Selection” also includes links to two of our most popular workbooks.
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There are ten key questions designers must have the answers to for a successful conversion from other materials to resin injection molding. Whether the design is for medical devices, business machines or for an industrial application, arm yourself today with this valuable infographic checklist.
Akron, Ohio, April 11, 2017: Demand for injection molded parts continues to grow as more manufacturers replace traditional materials like wood, steel and fiberglass with thermoplastic resins that are lighter in weight, but just as durable.
Designers and engineers in the medical, automotive, industrial, housewares, electronics and many more industries are increasingly asking whether a conversion to resin injection molding for certain parts and components make structural and financial sense.
To help designers and engineers get their first-time injection molding projects off on the right foot, Ferriot Inc. has produced the guideline, “Designing Injection Molded Parts: A Handbook for Designers & Engineers.” The booklet covers proper part design, resin selection and tips on how to select the right injection molder.
The guide offers readers an overview of injection molding processes and various applications and materials. Additional sections help readers determine whether a resin conversion and injection molding are right for their projects. When injection molding is the right decision, the guide recommends important questions to ask a potential contract manufacturing partner, and a project checklist to help both the designer and injection molding partner stay on the same page from start to finish.
Some key questions and project considerations suggested in the guide include:
Also included in the guide are a project checklist and spaces for notes and questions to be shared between the engineer/designer and injection molder.
The handbook is available online at no charge by visiting here. For more information on Ferriot and its injection molding and other contract manufacturing services, visit www.ferriot.com.
Ferriot Inc. is a full-service contract manufacturer and injection molder of engineered resins. Privately held since its founding in 1929, Ferriot employs veteran engineers and skilled technicians of the manufacturing and plastic injection molding industry. Ferriot’s contract manufacturing services include engineering, design, molding, sub- and finished assembly and delivery of components and finished products for a variety of industries including building and construction, medical, industrial, business machines, oil and gas, electronics and more.
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Today, so many different parts are being injection molded. These parts include laptop and mobile phone cases, medical and military electronic components, and a variety of other materials across industrial, consumer and specialty markets. Because of this, EMI and RFI shielding is becoming increasingly important.
Proper shielding for injection molded component parts is necessary to meet regulatory requirements as well as ensure continued, reliable performance.
Plastic parts are non-conductive. As such, they are not able to provide any sort of shielding on their own. This shielding works both ways. First, it prevents EM and RF from being emitted from devices housed within the injection molded cases. The shielding will also prevent outside waves from penetrating and interfering with the device’s operation.
Sometimes there is confusion over what is needed for a specific part or component. The reality is that the terms—to an extent—are so similar that they can be interchangeable, but there is a difference to note.
EMI stands for electromagnetic interference. EMI is defined as an electrical or electronic disturbance. This can be a naturally occurring phenomenon or something man-made. This disturbance is going to cause undesirable effects such as interruption or degradation of service.
RFI is short for radio frequency interference. The specific difference has a lot to do with the frequency at which electrical distortions fall between. So, all RFI is EMI, but not all EMI is RFI. RFI can be found at any frequency shared by radio transmission ranges—typically more than 1kHz to 10 GHz. Conducted RFI is usually going to be at the lower end of the spectrum, or, less than 30 MHz.
Virtually everything with an electrical signal causes some level of EMI or RFI interference. Fluorescent lights, radios, microprocessors, electric switches, networking equipment, phone lines, power cords, headphones, wireless devices, speakers and so much more. The problem used to be a lot more recognizable until we began working with different frequencies, power levels and better shielding.
If you set something near your television or laptop and see the screen dim, flicker, or otherwise distort, that is an example of EMI/RFI interference. Another example could be if you are having poor Internet connection speeds and you move the physical location of your router and the speed gets better—this is caused by a form of EMI/RFI. Static on a mobile call? It’s very likely the same problem. There are many common examples we all experience in our everyday lives.
There are some plastics that can be made condusctive with certain additives included. This is, however, very costly and therefore limited in use. Typically, plastic itself is not conductive. Because it’s not conductive, plastic cannot provide EMI / RFI shielding to prevent interference with your device or prevent your device from causing interference.
Conductive coatings solve this problem by adding shielding to injection molded components. This method has been in use for more than two decades and has consistently proven to be a reliable and cost effective means of shielding plastic parts. Conductive coatings are also favored for their lack of volume utilization within the unit.
Three key factors to consider when designing a part that will need EMI / RFI shielding are resin selection, mechanical/functional design and specific shielding requirements. Either the entire part or selective portion(s) of the part can be plated.
One of the first methods for adding conductive coatings for shielding is called electroless plating. Electroless plating is used to deposit thin metal coatings, from 0.00004” (1.0 µm) to 0.0005” (12.5 µm). Parts will go through a process that includes a chemical etching (to make the part rough) and an activation step which deposits a catalyst onto the surface to prepare them for being covered (or plated) with a layer of copper. Overall, the material properties of the resins remain unchanged; only the surface layer of the parts are being affected in this process.
This method provides a uniform thickness for the copper layer on the part. This includes part recesses and holes. Some applications will require applying additional copper on top of the initial layer, which will enhance the shielding’s effectiveness. The copper can then be plated with tin, gold, or nickel for environmental, electrical, mechanical, or cosmetic reasons.
Electrolytic plating—also known as electroplating—is for applications where thicker conductive coatings are necessary. This process applies metals at a thickness between 0.0002” (5.0 µm) to 0.003” (75 µm) or more. Electroplating comes after electroless plating when enhancing a part’s RFI shielding, providing additional metals over the initial copper layer(s). These metals include chrome, copper, gold, nickel, silver and tin.
Electrolytic plating is a different process that costs less and takes less time than electroless plating. The trade-off is that the application is based on line-of-sight and allows for a wider variation of the metal application to the injection molded part.
One of the earliest and most important decisions you will need to make during the engineering stage is deciding which resin to use for a part that needs to be EMI shielded. The resins that are capable of undergoing this process are referred to as plateable resins. Other resins are called non-plateable resins. However, even non-plateable resins can go through an RFI shield plating process if they are mixed through a custom engineered resin process first.
Resins commonly selected for plating include:
Resins that are difficult to plate include:
For help with the design and manufacturing requirements of injection molded parts that need EMI / RFI shielding, contact the specialists at Ferriot today.
When working with an injection molding company, many do not offer final assembly services. If you do find a contract manufacturer you are planning on working with that can take care of final assembly tasks, there’s a host of questions you will need to ask them. During the vetting stage, here are five of the most important questions to ask your contract manufacturer about their final assembly services.
ISO 9001:2008 requires that the company be able to consistently meet customer requirements when manufacturing parts. Other ISO certifications have specific emphases. Is the contract manufacturer you plan on working with certified?
You want a team with specific qualities. Search for a team that has focused experience in the product that you’re working with, or find a company that has a wide breadth of knowledge. This ensures that your manufacturing partner will know how to adjust quickly to your parts. They will also have the ability to see the production through to completion without any confusion or other roadblocks. Manufacturers with less experience may not be great at managing problems as they arise.
This is very important, especially with larger production runs. You want to be sure that the assembler and finishing team you have selected can handle the scope of work you need. They should have no issues storing, working on and shipping parts. Your manufacturer should also have the space to handle high volume demands without leaving parts outside or unorganized.
Some companies have a lot of experience managing a variety of critical tasks to help get your final stage product out the door. Other questions to ask that will help you better understand their abilities include:
One of the key reasons organizations rely on contract manufacturers to carry out final assembly work is cost savings. To lower costs, you’ll want to ensure that everything can be done in one place. This will add savings when it comes to logistics because you won’t have to ship parts from one location to another.
You can also save by ensuring you have the right partner when problems arise. The team carrying your product through from initial injection mold to paint to finish assembly have become intimately familiar with the parts. They fully understand how the part is supposed to work and the best way to handle it. If something should happen, and issues with parts are detected during assembly, you will want a company that’s familiar with your needs. That way they can solve the issue to get back up and running, which saves you time and money.
To learn more about selecting the right contract manufacturing partner download our free Contract Manufacturing Guidelines Tip Sheet.
Manufacturers need to be confident that they are providing their customers with quality products that meet agreed upon and necessary specifications. This is where a product quality audit (PQA) comes into play.
There are a number of different PQAs including the final quality audit (FQA), out of box audit (OBA) and others. The specific business needs will determine which kind of quality audit is best for your products.
There are three key ways for an audit to be conducted.
Read on to learn more about why you should run a PQA and how to ensure you have total quality management in place to get the results you desire.
When we discuss product quality audit it’s common to focus on the end product. However, other types of audits are important for a manufacturer to carry out as well. If you are using a contract manufacturer, you will want to be sure they are capable of handling product quality audits as well as surpassing expectations during process, management and other forms of audits.
The product quality audit steps and requirements should be decided upon before the manufacturing process begins. This would include designers and engineers working together with production managers to set reasonable expectations based on design, materials, manufacturing methods, machines being used and other criteria.
While injection molding custom parts, there are a number of items to review during a PQA. These may include wall thickness, orifice or cavity dimensions, coloration or finish, and any sort of strength/pressure/flex test that is required.
These steps should be completed before moving forward to final assembly. Final assembly and paint work will be done after the initial product audit, but then should also include its own product audit or FQA. This would include verifying functionality, flow, appearance, etc.
There are a number of reasons manufacturers should be carrying out quality audits for parts and assemblies. First, the part is designed for certain functions. If the part cannot perform those functions, it is defective. If it cannot withstand pressure, flex, or environmental tests, it will not last long in the field.
While some components are relatively innocuous—an ink pen tube, for example—other products are responsible for the safety and life of people who depend on them. If those products do not meet required specifications or perform as intended, it could cause grievous injury or even death.
Aside from that very serious (and legal) responsibility, manufacturers want to be sure they are producing quality parts because they do not want to handle an influx of returns and recalls. Such processes are costly in at least six ways:
Work closely with your contract manufacturer. There is a partnership where each of you is relying upon the other for success. They should be able to provide you with useful guidance regarding product quality audits and total quality management from their years of experience. They should also be fully familiar and comfortable with your company’s design and specifications. Never select a contract manufacturer that doesn’t clearly manage quality audits throughout the production process.
To learn how to get the most from your relationship with an injection molding contract manufacturer, download our free guide—Designing Injection Molded Parts: A Handbook for Designers & Engineers. Or, if you prefer, call us at (330) 786-3000 for immediate assistance.
Over the years, we have worked with a variety of different companies that all had different needs. This experience often lead us to discover interesting questions. When that happens, we always try to pass along the information, because we want customers to be knowledgeable and prepared.
Did you know that not all contract manufacturers do final product testing? Sure, they may carry out fit and function tests in the prototype stages, but they don’t go much further after that. It is an important part of proper quality control and your injection molding and assembly team should be carrying out tests throughout production runs at different points in the process.
Read on to learn more about how you can ensure that your manufacturing partner is taking all the right steps during and after production.
Without carrying out finished product tests, crucial elements can be missed. For example, everything may fit together, but a part could have become sheared during the assembly process. It is also possible for a part to get stuck in place during anodization, electroplating, or painting. There is also a chance for part failure, particularly with more complex plastic molded parts. Everything may have looked great on the design, but once the walls and cavities have settled and cooled, there is a chance for physical part failure.
You simply cannot tell these sorts of things without going through those additional testing steps.
There are a lot of companies out there with sterling reviews. You look and people only say good things about them on social media and company controlled pages. There never seems to be an issue. That right there should raise a red flag. Mistakes happen. It’s a fact of life.
The impressive part about a company is not that that everything is seemingly perfect, but more what action they take when production doesn’t go according to plan. To find out if your contract manufacturing partner is prepared by considering the following questions:
Different industries have different standards of testing and validation. You’ll want to know whether the contract manufacturer you’re working with is certified in the proper testing standards needed for your business. You should also ensure that they’ve kept up to date on the latest advancements with industry standards. You can verify this information by checking with the contract manufacturer and the certifying organization.
Ferriot is certified in a variety of standards and we work with companies in many industries including automotive, industrial, medical and more. Contact us for more details on how we can help you keep costs down and deliver on time. And, for best practices to minimize part costs without compromising your design goals download our free guide, Seven Ways to Cut Costs on Injection Molded Parts.
As we look to a new year, with a new president, it’s an excellent time to take stock of the U.S. manufacturing industry and where it’s headed. With a recent report from The Institute for Supply Management (ISM) showing the manufacturing index at the highest level since 2014, chances are it’s going to be a good year.
For some insight into this year’s trends, we turn to Printing Impressions and their article about what to watch out for in 2017. Some of the predictions include:
One category we find particularly interesting is the projected increase in custom manufacturing. While the article suggests that advances in printing technologies will offer opportunities for an increase in short production runs, we also believe that custom injection molding manufacturers will play a role in this trend. Contract manufacturers offer flexible options and experienced guidance for prototyping and low-volume productions that may be more affordable than 3D printing. Also, compared to 3D printing injection molders offer a wider selection of materials options.
For more insight on all the predicted trends read the full article on piworld.com: Manufacturing Trends to Watch in 2017
To learn how to get the most from your relationship with a contract manufacturer, download our free guide—Designing Injection Molded Parts: A Handbook for Designers & Engineers. Or, if you prefer, call us at (888) 667-0796 for immediate assistance.
No matter how much experience a person has and no matter how hard they try, there comes a point when we must all accept that we are only human. Mistakes can be made. This is one of the reasons it pays to have a final assembly service provider that understands your industry and end goals.
Making these mistakes when choosing a final assembly service bureau can be detrimental in cost overruns, delays and even recalls. Read on to learn how to avoid these potential barriers to success and profits.
Again, we are all human—even engineers. If your team of industrial engineers and design experts have looked over all the schematics and everything seems perfect, it is still a smart idea to have one last set of eyes to review the design.
A final assembly partner with engineers on their team has people who are involved with every aspect of production. Those people know how processes work in practical application, rather than just in theory. They are more familiar with specs and tolerances than those who are not familiar with finishing operations for final assembly.
These design engineers will catch errors others will others will commonly miss. Contract manufacturers that don’t offer this type of final assembly service skip an important step. This means that issues with clearances, solder bridging or incompatibility could go unnoticed.
Does this sound familiar? Everything on the CAD file looks great. Engineers from every team have signed off on the design. Production has begun and everything is going great. Then, something happens. There could be a shipping delay. There may be a defect with a shipment of components. Any number of issues can crop up when putting together complex, or even simple, assemblies.
An assembly service provider who also has parts sourcing capabilities is going to help make sure everything goes smoothly. First, they work with reliable sources and have a steady stream of incoming parts. Second, if something does happen, they have the ability to quickly make arrangements to keep production moving forward. This is possible because they have relationships and experience in the parts business that allows them to reroute orders, expedite new orders and otherwise avoid unfortunate delays that can cost you money.
It is not always the easiest thing to do, but press your assembly provider for details on what the different processes are to completely manufacture and assemble your components. You want someone who can do as much work in-house as possible.
This avoids delays due to shipping, other plants’ shutting down, or any number of additional issues that can be caused when your parts are in the hands of someone you are unfamiliar with.
From Pad printing to hot stamping to shielding and painting, you can rely on Ferriot and our more than 80 years of experience in the manufacturing business. If you are looking for the most economic and smooth transition for getting parts made, assembled and shipped, you owe it to yourself and your company to contact us today.
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Ensuring an injection molded product achieves its full potential demands careful planning. Much of this planning requires close cooperation between the engineer responsible for the design and development of the part and the injection molding contract manufacturer. The relationship between an engineer and a manufacturer will depend on a variety of factors, including the in-house resources available to the engineer and the level of assistance the contract manufacturing partner is equipped to provide.
If you’re an engineer, start with the following questions to ensure you’re making the most of your working relationship with your contract manufacturer.
If you’ve been working with the same partner for a long time, it’s easy to overlook resources and capabilities you’ve never taken advantage of before, such as:
Don’t hesitate to ask “what’s new,” even if you think you already know everything available from your contract manufacturing vendor.
Depending on your needs, you could have a variety of goals for production. Consider the following examples:
Maybe it’s some, or, all of these goals. Whatever matters most to you, make certain it’s spelled out clearly to your injection molding contract manufacturer, both verbally and in writing.
Particular part geometries can be difficult to injection mold. Some sizes, shapes and wall thicknesses can make the part especially prone to warpage, bowing and other defects. For example, unless properly placed and sized, features like snaps, undercuts, bosses, ribs, windows, etc., can complicate the molding process and increase costs unnecessarily.
Ask your manufacturer for guidance before you create a part design that will be difficult to mold or that might increase the part’s price.
Before your CM recommends a resin to be used to mold your product, discuss the key physical attributes that your end product requires. This discussion should include:
Identifying these attributes early will speed up the specification process.
Industrial injection molding operations have equipment that is most economical for parts within a minimum and maximum size range. Depending on the product, some facilities might be unable to produce a specific part due to the limitations of the equipment they have available. In addition, it is important to consider experience with different process technologies that can be applied to mold better quality parts.
For example, external gas-assist injection molding can be used to achieve sink free surfaces on thin-wall applications as well as for large flat parts such as enclosures, fascias and grilles.
Creating injection molded parts demands the use of a variety of testing and analysis techniques, both before the tooling is developed and afterward. The greater the precision achieved during the early test/analysis phase, the better. Time spent at this early stage saves money and rework later. Ask your injection molder about pre-tooling testing and analysis tools like these:
Confirm early that your contract manufacturing partner has the equipment and experience necessary to perform whatever tests are needed to determine whether a prototype part is ready to move into production. Depending on the part and how it will be used, this could include evaluations of drop or crash performance, low/high temperature properties, burst strength, static dissipation, wear resistance, moisture resistance, durability, structural compatibility, light transmission, shielding performance, sound dampening performance, part density, knit line strength, cracking resistance, or many others.
To learn how to get the most from your relationship with a contract manufacturer, download our free guide—Designing Injection Molded Parts: A Handbook for Designers & Engineers. Or, if you prefer, call us at (330) 786-3000 for immediate assistance.
Is there something else you’re looking for from your manufacturing relationship? Tell us about it in the below comments.
[post_title] => How to Get More From Your Injection Molding Contract Manufacturer [post_excerpt] => If you’re an engineer, ask questions to ensure you’re getting the most out of your relationship with your injection molding contract manufacturer. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => how-to-get-more-from-your-injection-molding-contract-manufacturer [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-how-to-get-more-from-your-injection-molding-contract-manufacturer/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [87] => WP_Post Object ( [ID] => 2449 [post_author] => 3 [post_date] => 2016-11-17 23:20:00 [post_date_gmt] => 2016-11-18 04:20:00 [post_content] =>
You’re thinking about making an injection molded part for your product. You want your part to be everything you hoped it would be, and it you want it to succeed in the world, long after your involvement in the project ends. Here are three ways you can conceive and deliver a great injection molded part.
You’d probably be surprised to learn that liability concerns drive many aspects of part design and production. It stands to reason that with so many product recalls in the news, companies are right to focus on the safety and reliability of the products they make. Reducing a company’s risk exposure and ensuring that end users are protected be
gins with concept development, all the way through to the design and manufacture of the injection molded part. This is the responsibility of every person involved in the production of a part.
In general, when a mission-critical molded product fails, it’s the OEM who assumes responsibility for the outcomes. This is especially true for medical products. That’s why the mindset for the manufacture of medical products of all types tends toward a risk-averse, conservative approach. Medical OEMs are looking for contract manufacturers who have experience with various ISO compliance standards, certifications, and familiarity with industry regulations.
Tip: If this is your first time at the injection molding rodeo, get to know your legal team early on in the process. They’ll be your partners during the development of an injection molded part, from conception to delivery.
Before you fire up your design software to crank out some CAD models, be sure to spend a long time detailing all the other aspects of your injection molded part. Where will it live, how long will it live, what will it be made of, and will it be profitable? Specifically, you and the team will:
a) There aren’t too many large-scale industrial resin producers in the market, so it’s a small world;
b) Environmental and risk factors have already been assessed and approved by the OEM's legal and quality team. (Remember when we said legal review was important?)
After you have the right concept and you’ve planned out how your part will live in the world, it’s time to bring it to life. A metal tool must be created that will be used to produce your parts. This is the object into which liquid resin is injected. In almost all cases, the customer will, for lack of a better term, “contract” with Ferriot to build a tool as part of the production of their injection molded part. On a handful of occasions, the manufacturer has supplied the tool directly to us. However, when multiple entities are involved in transferring a tool, the risk for error is increased. That’s why we prefer to keep this activity in-house.
Fabrication of the tool takes place domestically or overseas, depending on the customers desires and requirements. Ferriot will be responsible for determining how the tool is to be built and will ensure conformance to the customer's requirements. Once the tool is built, product samples are produced. If the tool has been transferred, Ferriot will produce a first article from the tool itself.
During the scope and evaluation process, the Ferriot engineering team will have used CAD data to develop key inspection criteria. This could be five key specifications, or it could be as many as thirty, depending on the complexity of the part. Using the first article off of the tool, the part is evaluated using these inspection criteria. It’s Ferriot’s responsibility to ensure this entire process happens smoothly. This is why partnering with the right contract manufacturer makes all the difference.
After the tool and first articles pass inspection, you’re ready to start making molded parts in quantity. If you plan well, each warm, plastic molded part that rolls off the production line will embody the characteristics you’d hoped for, and will be ready to fulfill its purpose in the world.
For a detailed paper on how injection molded parts are produced, download our PDF, "How Injection Molding Happens: The Step by Step Production of a Medical Device Part." Click the image to get the paper:
If you’re ready to ask specific questions about your injection molded parts development process, complete a request for quote form. Or, if you prefer, call us at (330) 786-3000 for immediate attention.
[post_title] => What To Expect When You're Expecting an Injection Molded Part [post_excerpt] => A high-level overview of the production process for an injection molded part. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => what-to-expect-for-injection-molded-part-production [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-what-to-expect-for-injection-molded-part-production/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [88] => WP_Post Object ( [ID] => 2452 [post_author] => 3 [post_date] => 2016-10-25 19:33:00 [post_date_gmt] => 2016-10-26 00:33:00 [post_content] =>Ferriot, Inc. has been around for more than 80 years and boasts a proud tradition of being a family-owned business. The company was recently recognized with a special award during the 2016 Smart Business Family Business Conference. The annual conference is a result of the partnership between Smart Business and Cuyahoga Community College (Tri-C), and features an interactive workshop format to discuss how family businesses can plan for a smooth transition.
This year, Craig Ferriot was awarded the 2016 Family Business Achievement Award, showcasing the company’s dedication to excellence and the local community.
Ferriot, Inc. has come a long way since three brothers started their machining business back in 1929. Five generations later, the company continues to grow. Currently, the company employees three generations of the family that started it all.
Craig and his team of 120 employees are leading the way with injection molding production for a wide variety of businesses, including those who manufacture consumer products, automotive, medical devices, and more.
The company focuses on being able to deliver big--through smart investments in technology, processes, and people--while still remaining small. This allows them to be both agile and lean, able to help their growing customer base in varying and fluctuating markets.
Ferriot offers the full array of necessary services for their OEM customers. This helps to ensure end-to-end compatibility and heightened sourcing quality. Ferriot’s wide range of experience has made them the go-to contract manufacturer for many businesses.
Smarter, more efficient manufacturing and assembly processes are the key to Ferriot’s continued success. This requires the team to stay up-to-date with the latest technologies and manufacturing techniques.
The award highlights the role that innovative, family-owned businesses play in their local economic and educational landscape. Tri-C is a nationally recognized, leading educational institution with a strong commitment to preparing today’s students for tomorrow’s workforce. They also work to build the surrounding communities both economically and culturally. More than 85 percent of Tri-C’s students continue to live and work in the area after graduation. "We know and understand that family businesses are an important part of the fabric of our community, and we remain committed to helping family businesses succeed and thrive," says Alex Johnson, Ph.D., president of Cuyahoga Community College.
As a kid I had a toy that purported to answer questions about the future. Wouldn’t it be great if we had a Magic 8 Ball® to answer life’s big questions? Should I marry this person? Should I buy this house? We would be able to make the decisions that get the happiest results.
While this is just a fantasy, when it comes to custom injection molding, actually there is a way to predict the future using plastic injection-molding simulation software. Enter the geometry of the part (via a CAD model), specify parameters such as the type of resin, locations of the feed system and vents, injection pressure and temperature, and then watch what happens. The goal is to anticipate problems via simulation, without incurring the significant cost of creating a mold. When we review the results, we may tweak certain parameters of the molding process and then run the simulation again. By optimizing the tool design, we can improve part quality, shorten cycle times, and above all, avoid the need to rework a mold. If necessary, we work with our customer to modify the design and resin selection to achieve the best results.
Here is a rundown of the useful ways simulation software can improve your design and lower manufacturing costs.
Injection pressure. The software predicts the injection pressure at switch over, which is usually 99% of complete fill. Lower pressure is better as it facilitates manufacturing.
Cooling time. As the animation continues, we see the part cool. Colors indicate the various temperature ranges. Knowing how the molded part cools is helpful in specifying the packing/pressure hold time and predicting the speed of manufacturing.
Temperature at the flow front. As the resin fills the mold, the resin is cooling. You don’t want resin in areas of the mold to cool and harden before the rest of the part is filled, because that could introduce quality issues. The software predicts the temperature drop at the flow front. This type of information helps us strike a balance between fill time, injection pressure and other key process parameters.
There are even more ways to use the software, but I think you get the point. Obviously, simulation software is no child’s toy. It is a powerful tool for reducing cost on your injection molded project. Consider involving a molding expert who can assist you with this type of analysis.
Using software is only one way to save money on your project. There are several more, explained in our guide, “Seven Ways to Cut Costs on Injection Molded Parts.” Click the button to download your free PDF tip sheet.
If you’re ready to ask specific questions about your injection molded parts development process, complete a request for quote form. Or, if you prefer, call us at (330) 786-3000 for immediate attention.
(By the way, the lawyers want me to tell you that Magic 8 Ball® is a registered trademark of Mattel. Moldflow® is a trademark of Autodesk, Inc.) [post_title] => Avoid Molding Mistakes with Injection Molding Simulations [post_excerpt] => When it comes to custom injection molding, there is a way to predict the future using plastic injection-molding simulation software--and it'll save you money. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => avoid-molding-mistakes-with-injection-molding-simulations [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-avoid-molding-mistakes-with-injection-molding-simulations/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [90] => WP_Post Object ( [ID] => 2459 [post_author] => 3 [post_date] => 2016-09-02 10:00:00 [post_date_gmt] => 2016-09-02 15:00:00 [post_content] =>Creating a successful injection molded component is never a solo accomplishment – it involves multiple people with a range of expertise. One of the most important areas of expertise is the selection of the resin to be used. You’ll want the resin that best suits your design goals, performance specifications and budget—and a great team of injection molding experts to help you engineer your solution. Here is a quick overview of the 12 steps you and your team can employ as you think about the right plastic for your project:
Analyze part geometry. Part size, shape and wall thickness could make the part especially prone to warpage, bow, and other design issues. The sooner our engineers can review the part’s configuration with Moldflow® analysis and suggest changes to optimize its moldability, the earlier we can begin to narrow the list of appropriate resins. (Moldflow is plastic injection molding simulation software that helps us determine the best design.)To streamline this resin selection process and move components into production as seamlessly as possible, Ferriot has developed an Injection Molding Resin Selection Workbook. Click the button to download your free PDF.
If you’re ready to ask specific questions about your injection molded parts development process, complete a request for quote form. Or, if you prefer, call us at (330) 786-3000 for immediate attention.
[post_title] => 12 Steps for Choosing the Right Injection Molding Resin for Your Part [post_excerpt] => Choose the best injection molding resin to make your part. Use this worksheet to properly scope your design and execute your part. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => 12-steps-for-choosing-the-right-injection-molding-resin-for-your-part [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-12-steps-for-choosing-the-right-injection-molding-resin-for-your-part/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [91] => WP_Post Object ( [ID] => 2461 [post_author] => 3 [post_date] => 2016-07-14 16:00:00 [post_date_gmt] => 2016-07-14 21:00:00 [post_content] =>Insert molding is another type of injection molding (IM) process: In this process an insert is placed in the mold either manually or through automation before injecting resin material around it to secure it in place. This insert can be made of different types of metal, including steel and aluminum and/or non-metal components. In some instances, the inserts are simple designs such as electrical leads, fastener, pins, or sheet metal. Other times, wire meshes and plates are used as inserts, strengthening the final product of the injection molded unit. These are not the only options for injection molded inserts—more complex designs can also be molded as inserts.
By molding around inserts, this technique of injection molding can reduce assembly and labor costs as compared with incorporating the elements in final assembly. Because the insert is efficiently placed as part of the IM process instead of being placed after molding, the part can also be made smaller. No fasteners or mating joints are required. Design flexibility is a key benefit to insert molding as well as other overall improvements: increased component strength and decreased part size and weight.
The tolerance requirements for molding around an insert are relatively tight. In this process, the resins are being molded around a pre-existing unit. If the mold is off by even a fraction of a millimeter, the part will not function as intended. Ferriot’s design and engineering team works closely with our clients to ensure that the strictest tolerances are consistently produced. We also have several solid partnerships with vendors to provide on-spec metal (and non-metal) inserts for injection molding. Realizing all the benefits this type of IM technique can offer
means getting it right—with the right design partner.
Verifying the design and tolerances for the component(s) to be injection molded is key, but there are other things to consider, too. The insert must be able to withstand the extreme temperatures and high pressure of the injection molding process. For this reason, it is imperative that you are familiar with the insert provider and their ability to maintain consistent quality. Consider, too, the initial tooling design cost could be increased due to the fact that the molds will need a way to “hold on” to the inserts until the resin can be injected. Sometimes, tool designs leverage the benefits of bosses or undercuts to offer enhanced retention strength. Creating a reliable way of doing this that lasts the entire duration of the project run can be tricky. Our design and engineering team will work with you to help meet your specific needs while keeping costs down.
If you’re considering a specific project, you may be wondering:
If you’re ready to discuss your project details, contact us for a quote.
[post_title] => The Benefits of Insert Molding in the Injection Molding Process [post_excerpt] => What are the benefits of insert molding over other types of injection molding? Can it make your parts better? Can it save you money? Click here to find out now! [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => the-benefits-of-insert-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-the-benefits-of-insert-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [92] => WP_Post Object ( [ID] => 2463 [post_author] => 3 [post_date] => 2016-06-29 14:30:00 [post_date_gmt] => 2016-06-29 19:30:00 [post_content] => Ferriot, Inc. was featured in the July/August issue of Manufacturing Today magazine. The full article discusses three key areas that assure the success of any contract manufacturing endeavor. Here's what you need to know if you're looking for the best manufacturing partner for your unique assembly challenges.
incredibly complex, riddled with the potential for derailment or missed deadlines. That's why it's important to select a contract manufacturer with the right expertise who can drive the process from start to finish. For thermoplastic injection molding of engineered resins that process begins with mold creation. From there, an ideal partner will take the client through supply-line development and management, process qualification, product testing and final assembly. Handling the drop shipping of the finished material is a final service that frees up client time and attention, and knowing that the job will be delivered properly and on time is invaluable. "One-stop shopping" with an experienced partner delivers peace-of-mind as well as convenience and cost efficiency.
Choosing a contract manufacturer with the expertise to guide a client from end-to-end becomes particularly important for specialty operations such as insert molding, high pressure structural foam molding, gas-assist molding, and overmolding. Even more complexity is introduced when additional finishing is required:
[post_title] => Three Ways a Full-Service Contract Manufacturer Adds Value
[post_excerpt] => What should your contract manufacturer bring to the table? Here's what you need to know if you're looking for the right total manufacturing partner.
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Decorative metallic coatings allow plastic parts to function as lightweight, economical alternatives to metals in a variety of applications (i.e. automotive, appliance, business machines, etc.). One such process is electroplating, which provides a high-quality, durable finish to plastic. Today, plating grades of ABS and PC ABS meet the stringent performance requirements of automotive and appliance applications.
This article focuses on two important front end processes, plastic part design and injection molding specifically for electroplating. Both significantly influence the success when plating a plastic part.
Let’s begin by talking about plastic part design and what should be considered when designing and building a plastic injection mold. Keep in mind, that defects on highly cosmetic surfaces will be more pronounced after electroplating. Following best design practices will help optimize the appearance and keep rejects at a minimum:
These key points discuss how to best optimize the injection molding process for improved plating adhesion and end-use performance:
There are many subtle nuances to proper processing of plastic parts to be electroplated. Ferriot has many years of experience in the molding, decorating and assembly of plastic products and understands the steps necessary to insure success in producing electroplated plastics.
Here at Ferriot, we are proud to be a leader in thermoplastic injection molding since the 1940s. Our clients turn to us for professional assistance with contract manufacturing, custom injection molding, painting, and assembly. Structural foam is one of several injection molding processes we offer.
Traditional injection molding is typically done in two stages. There’s an injection stage where melted thermoplastic is injected into a mold, and a packing stage where pressure is built and the plastic is formed into the shape of the mold. In structural foam molding, the injection stage is basically the same, but the packing stage is augmented by a chemical blowing agent mixed with the material. That chemical blowing agent is triggered by heat and expands the material by creating a microcellular structure to form the part against the mold.
A part made using structural foam molding offers a number of advantages. They generally weigh less and aren’t as dense as similar parts manufactured using other processes. This is the end result of the blowing agent which, essentially, creates a thermoplastic foam within the mold. Actual weight savings can vary, but parts made using structural foam molding can be as much as 10% - 30% lighter than other parts, while retaining durability.
This process also scales well, allowing large or bulky parts to be manufactured while still retaining the superior production speed offered by injection molding. Structural foam parts can be finished by methods typically used for other plastics. The surface of a finished part is smooth offering the potential of easy cleaning, and can be painted over.
An additional benefit to parts manufactured using this process is part durability. As a result of the difference in process, parts have excellent stiffness-to-weight ratio.
We’ve been busy putting structural foam molding through its paces to manufacture a variety of parts, including a gasoline dispenser front facia for use at filling stations and the results have been everything we could have hoped for. Along with the durability offered by the new parts, the material options available for structural foam molding also means a finished product can be chemical resistant, offer electrical or thermal insulation, and can be developed for outdoor applications.
Think this might be an alternative solution for you? We encourage you to contact us to discover how Ferriot can benefit your business.
[post_title] => Expanding Options With Structural Foam Molding
[post_excerpt] => Structural foam offers an alternative to traditional injection molding.
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[post_content] => Recently, FirstMerit Bank’s magazine, Merit Matters, published an article featuring Ferriot, Inc.’s President Craig Ferriot. The article discusses Ferriot, Inc.’s history as well as how the legacy continues.
For more than 50 years, FirstMerit Bank has assisted Ferriot with all of its banking needs. One of the reasons that this relationship has endured, other than both being based in Akron, is due to the similarity in the two organizations’ values. Mutual feelings of trust and alignment have also played a large role in this continued partnership.
As Ferriot has continued to evolve and grow, FirstMerit has been there to support them through a diverse suite of financial tools. These tools include:
FirstMerit has “been top-notch in responding to our needs as a company. They work very hard to understand what our needs are, and they are excellent at delivering what they promise,” says Craig Ferriot. Another trait shared by both companies.
To read the featured article, and learn more about Ferriot, Inc.’s beginnings and future, please click on the button to download a printable version of the article.
[post_title] => Continuing a Legacy [post_excerpt] => Recently, FirstMerit Bank’s magazine, Merit Matters, published an article featuring Ferriot, Inc.’s President Craig Ferriot. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => continuing-a-legacy [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-continuing-a-legacy/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [96] => WP_Post Object ( [ID] => 2474 [post_author] => 3 [post_date] => 2015-12-07 05:00:00 [post_date_gmt] => 2015-12-07 10:00:00 [post_content] =>
Akron, Ohio, December 7, 2015: Ferriot Inc., a custom injection molding and contract manufacturing company, has appointed Dave Harman to the management team to achieve sales initiatives in key markets. Dave joins Ferriot as Director of Sales and Marketing where he will oversee both Ferriot and its wholly owned subsidiary, American Original Building Products. Dave brings over 30 years’ experience in sales and sales management with Fortune 500 companies as well as small, family owned organizations. As a business owner, he fully understands a balance sheet and a P&L and how to make an operation run successfully. As a sales manager, he takes leadership and profitability seriously.
Already committed to a career in sales and sales management, Dave had developed a successful track record with experience in both the large corporate world as well as the small business arena with companies such as Conoco/Vista and Amresco. But it was Sandler’s systematic approach to selling and leadership that took his success to a different level. Learning and implementing the behaviors, attitudes, strategies and techniques available through Sandler’s model of on-going reinforcement training and coaching, Dave consistently, incrementally, and dramatically improved sales and profits.
After many years as a Sandler Training client, his passion for sales drove him to join the Sandler team to pursue his desire to help other sales and management teams grow in the areas of sales, leadership and professionalism. He is devoted to working with salespeople, sales managers, executives and business owners who are just as committed their own professional growth.
Craig Ferriot, President of Ferriot, Inc. said, “Dave brings a wealth of experience in the sales arena and with the increasing demand for exceptional support and service by our customers, his knowledge and leadership will provide the expertise that we are looking for as we continue to develop our sales team and grow our customer base.”
Ferriot Inc. is a full-service contract manufacturer and injection molder of engineered resins. Privately held since its founding in 1929, Ferriot employs veteran engineers and skilled technicians of the manufacturing and plastic injection molding industry. Ferriot’s contract manufacturing services include engineering, design, molding, sub- and finished assembly and delivery of components and finished products for a variety of industries including building and construction, medical, industrial, business machines, oil and gas, electronics and more.
Two major impact areas for product development engineers.Designing new products is a very tough job; there is so much to do and little time to make it happen. Speaking specifically about molded plastic parts, four critical areas usually blend together in successful product designs. The 3D part design, material selection, tool design / construction, and simulation /processing. If not impossible, it would be extremely difficult to find any one person who can do it all. This is why it is so important to have molding partners that can help share the weight of the new product development process.
Product development engineers usually lead the way in part design and material selection, but these activities can also be passed to suppliers in some cases. Brad Martin’s post on November 25th 2014, “7 Key Aspects to Identify When Designing Injection Molded Plastic Parts,” discusses some high level critical questions that need to be asked at the beginning of the part design process.
The second major impact area for product development engineers is material selection. Once you have summarized critical design requirements you can begin to narrow your list of preferred materials. This can be done by referring to your company standards, searching material databases, searching the internet, contacting your preferred raw material suppliers or contacting your molding partners. The goal would be to meet all your critical part requirements and to narrow the list down to a couple strong candidates for further consideration.
Once you have a preliminary part design and a few possible material selections you can now begin to accelerate the concurrent engineering process with your supplier and optimize your design.
Key outputs from the concurrent engineering process should be:
Contract manufacturers come in many shapes and sizes. Some are large international companies with sites around the world that are finely tuned lean manufacturing machines. Others serve a niche and may be an American Small Business.
The large international contract manufacturer is set up to make hundreds of thousands of the same product and do so extremely well. There are times that those large volume products require a machine that consumes or dispenses them. These machines themselves are a low volume, high mix build that is not attractive to same company but are part of the deal. The size of parts, right manufacturing processes, sources of supply, and order fulfillment process are not the same for the machine and the consumables.
This creates the need for a supplier to the large contract manufacturer to produce parts such as machine enclosures or panels that are part of a much larger machine. This could include more specific processes like structural foam injection molded panels, gas-assist injection molding to accomplish special cosmetic needs, or insert molding that will embed a hinge pin or metal plate.
These enclosures or ‘outside skins’ also need decorating. This could include painting, pad printing, or addition of decals.
Special functionality such as EMI/RFI shielding is also quite common with such enclosures.
While providing the parts and the variety of value-added services, it may also make sense to add other componentry so the large contract manufacturer is managing fewer SKUs.
When this is all put together, the supplier that starts with some primary parts, adds finishing operations and componentry and simplifies the works of their customer, the large contract manufacturer. Just like the contract manufacturer is simplifying the life of the OEM.
Ferriot has enjoyed its place in this process of supporting the large contract manufacturers and OEMs over the decades.
Keeping a competitive edge in today’s market requires speed and agility when launching new products. Time to market for new products has become further and further compressed. Early engagement with a full service plastics partner can steam-line your development process and accelerate your time to market.
Here are six ways a full-service plastics partner can help your business reduce time to market for new products.
Have you ever experienced making samples of a new product on a 3-D printer and then being told that the product was not manufacturable? By engaging a plastics partner in the initial stages of your design you can save hours of effort. A plastics expert can provide input on what design features are possible from a manufacturing standpoint. This will allow you to design with manufacturability in mind and save hours of effort by eliminating the number of design iterations required. A plastics partner should be in integral part of a collaborative process with all stakeholders in new product development.
Designing an injection mold is both an art… and a science. Working with experienced Tooling Engineers is critical to creating an optimal mold design and optimizing the development process. Experienced engineers will consider how best to accomplish all design aspects of a mold. A qualified engineer will consider options that include identifying actions to create part features, holes, recessed features, windows and inclusion of inserts. A well designed mold can eliminate additional steps in the manufacturing process later.
Picking an injection molding company that has multiple injection molding processes will improve your chances of getting the best process for your part.
These would include straight injection molding, structural foam molding, gas assist molding, insert molding and over-molding. Each process has its own attributes that will satisfy particular product needs. A qualified plastics partner can help you to identify the ideal method to provide a quality part.
Most plastic parts will require some form of finishing such as pad printing, ultrasonic insertion, hot stamping, painting or EMI/RFI shielding. Selecting a plastics processor that includes these operations under the same roof will provide the most efficient manufacturing process. This can take weeks out of the lead time to produce a finished part.
Utilizing a plastics partner that can also source components and provide assemblies can simplify the OEM’s manufacturing process and drive cost savings. By providing supply line development and management, your plastics partner can economically source materials from qualified suppliers, reducing supply chain risk for the OEM. Assembly capability under one roof provides cost savings by eliminating additional shipping and assembly cost.
Engaging with a plastics specialist can help your company achieve optimum efficiency and profit while producing quality parts. Whether you are taking a product from concept to completion or transferring an existing mold project, effective quality management practices are an important factor. A qualified plastics partner has procedures in place for mold, part and process qualification and has documented processes that will ensure production quality. Trained & experienced engineers will follow standard testing methodologies including FMEA methods and utilize the right testing equipment for part qualification.
Optimizing your new product development process is a strategic imperative where the first to market with a new product enjoys a competitive advantage. Engaging a qualified plastics partner early in the new product development process can help you to accelerate your time to market by saving time and investment cost and delivering a quality product.
.The above points should speak for themselves when it comes to making the production of your new plastic piece easier in the long run. By taking the time for due diligence in the early stages, you’ll not only save time and money – but you’ll be much more confident and secure that everything is done to your specifications for on-going production orders.
Painting plastics is not easy, as special paints are required to give your parts the desired finish and ensure it bonds well with the plastic. However, painting techniques have evolved over the years and there are several different means by which the plastic parts can be painted to meet any need. Below are two main reasons why plastic parts should be painted:
Completely unrelated to functionality, the details below discuss options if you are looking for a flawless finish.
If your pieces need to be uniform and you require a custom color, it will be less expensive and more pleasing to paint the pieces rather than create a custom resin. OEMs choose to use painted plastics because resins may not offer the desired effect or color.
When it comes to testing painted plastic molded parts, color uniformity is the main thing that comes to mind. Paint will enhance the appearance of the plastic and will help you to match custom colors exactly.
This is the idea of producing mass plastic products that have been tailored to your desires and needs. Producing a variety of colors in a molding press is impractical, particularly when the plastic colored parts that are required are small.
Paint helps to conceal the imperfections of the mold and/or surface conditions that are a result of the injection molding process or part geometry. Some of the imperfections include:
As a customer, you may want a higher gloss finish than the resin is capable of providing. Paints can achieve a wide range of gloss levels, which will make it easier to achieve your marketing objectives.
While painting not only allows for improved aesthetics, the functionality of your plastic part can be increased through painting, as described below:
Paint can improve protection of plastic molded parts from a broader range of chemicals and other substances that can stain it.
Most cleaning chemicals in the market today are harsh and can reduce the physical properties of some plastics over time. Paint helps to protect the plastic parts.
The smooth finish makes cleaning the plastic easy. There are no scratches or stains that would make it hard to clean or give dirt and dust a place to hide.
Paint makes the plastic surface harder so that it will not be as easily scratched, helping to avoid abrasions.
UV coating is a perfect choice if your plastic parts will be outside. A number of plastics are sensitive to exposure to sun, the ozone, salt, and acids. Paint will help to protect the plastic.
Understanding the effects of paint on plastics is a key to improving the appearance and performance of your molded plastic part.
Pad printing is an innovative and effective process for transferring a two-dimensional image onto a three-dimensional surface. It can also be a delicate process with numerous variables that can lead to an unsatisfactory image transfer if done incorrectly. My goal in this post, assuming the reader has a basic understanding of the pad printing process, is to touch on a few of the more frequently encountered problems that cause poor image transfer and how to troubleshoot them.
In my experience with pad printing, the three most commonly encountered problems that arise while printing on a job are as follows: an incomplete print or a print featuring excessive voids, distorted and blurred prints, and the pad carrying excess ink or dirt outside of the desired image. Before touching on the three said problems it is important to state that starting a job under ideal printing conditions and practicing preventative maintenance on your equipment is going to be the most important part of achieving good transfer and maintaining that good transfer over a period of time. Having clean blades, cups, pads, and clichés along with ink mixed to the vendor/manufacturer’s recommendations is vital to a successful start up. If good start up practices are taken and problems still arise, then hopefully the simple troubleshooting tips below will help.
If any job runs long enough you will eventually begin to see voids within the print or begin to see incomplete prints all together. This is due to the evaporation of the solvent, or “thinner” from the ink, which in turn makes the ink thick and resistant to a clean transfer. 85% of the time, the correct and the only needed course of action is to mix in more solvent. The other 15% of the time, when thinner is added and the poor print still persists or rapidly reemerges, there are a few possible solutions:
When ink is mixed correctly but the transfer is still flawed, then the silicone pad or the cliché are most likely the cause. Any bending, bowing, or abnormal curvature to an image that has been transferred can be attributed to the pad. When a pad strikes the cliché or the surface of a part too hard, the smashing of the pad will distort the print during transfer. The pad should only strike hard enough for a complete ink pick up and a complete ink transfer. Too much pressure runs the risk for distortion and too little pressure will lead to an incomplete print. The same problem can occur when the shape of the pad does not fit the contours of a part. Make sure manufacturers and suppliers are involved when new pads are made for new programs and that clean undamaged pads are used in production.
Just as detrimental as incorrectly handled ink and pads is a damaged cliché. Any scratch or knick deep enough for ink to seep into will be transferred over to an image if the pad strikes that particular area of the cliché. Precautions need to be taken to maintain the surface of clichés and prevent rust.
The above maintenance and troubleshooting recommendations should correct the three common issues mentioned above. If you encounter these problems in your pad printing process or other common issues leave us a comment below to share troubleshooting tips or questions.
There are many variables that impact the success of injection molding a good part. One of these variables is injection machine screw choice. When it comes to screw choice, choosing the right screw geometry for your project is crucial to success. It will ensure there is no material degradation and that the material will have been properly melted. This will result in less stress in the part, less scrap, and proper size and weight.
In today’s environment, injection molders need to be making parts as efficiently as possible in order to keep manufacturing costs down. Using the right injection screws for your customer’s parts will play a significant role in this. There are a few things you need to know first, such as how a screw works and how to match a screw to the type of polymer you plan to use.
The basic design of any injection molding screw has three zones along the length:
The feed section conveys the solid plastic pellets to the transition section where they are compressed by a change in screw geometry (the channel depth). This compression forces the pellets to melt through the action of pushing up against each other, which is called shear. The metering section then conveys the melt to the front of the screw, ready for injection into the mold cavity.
In the picture above you see a general purpose feed screw. If you are running polypropylene (PP) or polyethylene (PE) with no additives, this type of injection screw will work great. At Ferriot’s custom injection mold shop, we run polycarbonate (PC), Nylon, Delrin and blends of different polymers with fire retardant, UV stabilizers, glass filling and lubrication. (How they fit all that stuff into a little tiny pellet I will never know, but they do.)
When you try to run PC on a general purpose screw, the material will burn in the compression section of the screw. This is because it forces too much material into the compression section and causes too much shear heat and burns the material. You can make process changes to adjust for this by lowering the pressures and heat, but this will cost you cycle time. The correct screw design would have a short feed section, a long compression section and a short metering section. The long compression section is gentler on the material, so it eliminates burning.
There are many different configurations of feed screws – some for mixing color or additives and some for different materials. They have different coatings and are made of different materials and have flights and root sizes configured for specific situations. One piece of advice is to ask the people that make injection molding feed screws what will work best for the particular situation as they are very knowledgeable and have seen most process issues before. Material vendors are also an excellent resource for determining optimum screw configuration.
In today’s world of manufacturing and new product development, the need for fast-paced production and the existence of complex designs is greater than ever. Historically, manufacturers have depended on metal due to an existing wealth of metal knowledge, it’s strength and stiffness, perceived quality, and ideal properties related to electricity, UV performance, and chemical resistance. However, due to a fluctuating economy, high cost of goods, and smaller margins, the need for materials that can reduce weight, cost, and production time is huge.
Although metal-to-plastic conversion has been around for decades, many manufacturers, Commodity Managers, and engineers aren’t familiar with the benefits. With proper design, engineered plastics and high performance resins can be just as strong as metal. According to the American Society of Mechanical Engineers, “in general, companies can expect to achieve an overall cost savings of 25% to 50% by converting to plastic parts.
There are many factors that drive metal replacement, however the main three include:
When beginning the process of determining if metal replacement is the right move, we typically recommend utilizing DFMA (Design for Manufacture and Assembly) – a systematic approach for evaluating and generating product designs for ease of assembly and manufacture. The best time to use DFMA is when it can influence the conceptual stages of a product. For example, is there a potential for parts consolidation? Are there quality or ergonomic issues? Are the current assembly operations too complex or expensive? These are all important questions that help ensure you are taking a systems-solution approach, which is critical for successful plastic-to-metal conversion.
Plastics have been highly successful in replacing traditional materials in applications where they can provide value through improved performance at lower systems cost. Here are some of the benefits of replacing metal parts with plastic ones:
In summary, metal replacement is largely driven by system cost reduction. Plastics may offer additional performance advantages, such as weight reduction, impact improvement, and corrosion resistance. The most impactful metal replacement successes typically require a cross-functional team reviewing an entire subsystem, rather than a one-for-one replacement.
When I initially joined the building products industry in the year 1999 there were 30 + Manufacturers of Vinyl Siding… Fast forward to today, and it’s now down to 9… mostly through consolidation. It remains the #1 Choice for exterior cladding across the US, primarily due to its low cost and maintenance freedom. And it looks EXACTLY like it did in 1999, nothing has changed.
People have been driven to this product over the years because it was the closest thing to resemble wood, without having to paint it, stain it, or maintain it…
GOOD NEWS! You have an alternative… Injection Molded Polypropylene Siding, and here are 5 reasons why:
1. Curb Appeal: Next time you are driving down your street, take a look at the other homes. Do they look alike? Or at least similar? Polypropylene Siding is offered in 4 primary profiles: Traditional Cedar (most popular), Hand Split, Scallops (or Half Rounds), and Cape Cod. They can be used to cover the whole house, or simply as an accent. You can choose to use comparable or contrasting colors…it’s up to you!
2. Twice As Thick: On average, Polypropylene Siding is twice as thick as traditional vinyl siding. The added thickness provides better impact resistance against things such as hail and falling tree branches. The increased thickness adds weight to the product, making in more wind resistant, and therefore far less likely to blow off during a storm
3. Looks Like Wood: No really, it does! Deep, three dimensional wood grain provides the natural look of wood. The unique surface treatment of the mold removes the “gloss factor”, no more shiny looking plastic on your home!
4. No More Seams: An inherent problem with vinyl siding is that it can’t be installed properly without lapping the panels every 12 feet, therefore creating a visible vertical seam from the bottom to the top! In addition, vinyl siding expands and contracts as the seasons change (hot to cold, cold to hot). After a few years, this expansion and contraction often causes the seams to become even more apparent. Polypropylene Siding butts together, end to end, no need to lap! Various key widths make finding a seam virtually impossible.
5.Environmentally Friendly: Throughout its life cycle, Polypropylene Siding is more environmentally friendly and sustainable than vinyl siding, as well as most other exterior cladding products, and is 100% recyclable…
For most, the home is the biggest investment you and your family have. Most people side or re-side their home ONCE, so I encourage you to do it right the first time. Do yourself a favor and ask your contractor or builder to show you what’s available in Polypropylene Siding… you will be glad you did!
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Contract Manufacturing is a process that's about more than getting the parts you need. Here at Ferriot, we think of it as a partnership - and like any good partnership, that means working hard to ensure you get what you need.
Working with a contract manufacturer can allow for someone else to:
Manufacturing is complex, but we don't think it should be more complicated for you than it needs to be. Contact us today for more information about the contract manufacturing process and what we can do to solve your manufacturing problems.
One may wonder how it is possible for a plastics company located in Akron, Ohio to work with multi-national companies, serving their international market needs. For international companies that sell their product all over the globe, it does not make sense to invest in several production regions around the world. Instead, companies will partner with supply chain manufacturers in their own country to assist with subassemblies of their final product.
Supply chain manufacturing companies typically develop the part we’ve been contracted for and then we work to ship that part to the next facility for final assembly. This allows the company developing the product and the companies that work to build that product to act as more of a cohesive team. Since we are typically just a piece of the puzzle, attention to detail is crucial. Ordering, scheduling, tracking arrival times, and part inspection all play a role in the supply chain manufacturing process.
As new part qualification has become more sophisticated with First Article Inspections, Capability Studies, PFMEAs, etc., it is fastest and most efficient for the interaction with the New Product Development Team and Supplier to be in the same country. And Time-to-Market is forever being compressed.
Typically, it makes the most sense for a company to begin production where they plan to focus their new product development. If you’re a U.S.-based company, even if you sell your product elsewhere, it makes sense to work with a U.S.-based supply chain manufacturer. This allows the product development team and engineers to have easy access to the product and makes it easier to communicate with the supply chain management team.
Ferriot worked with a company that originally had both its innovation center and manufacturing facility based in California. The company moved the manufacturing to Costa Rica, however, with the innovation team still based in California, it made sense to keep the part-creation process in the U.S. as well. Ferriot ships that part to Costa Rica instead of California. This allows Ferriot to act as the specialist for the product, no matter where it has to go.
Are you a company working on product development in the US? If so, how do you handle your production?
To learn more about part creation, check out another blog post:
7 Key Aspects to Identify When Designing Injection Molded Parts
Several points should be taken into consideration when deciding to move injection molds from one supplier to another. The ideal solution is one in which the existing supplier, new supplier and customer are able to openly communicate while maintaining all customer deliverables in the process. However, when this is not possible, having a supplier that has experience with this type of transaction is extremely invaluable. There is no substitute for experience and comprehensive planning.
The following Mold Transfer Guidelines provide key points to consider when transferring molds:
This will cover the time necessary for the new supplier to put the essential provisions in place to transact future business uninterrupted. If the buffer is too small, it will put undue pressure on all parties, requiring alternative plans without sufficient time to execute.
Ample time should be given to:
Current Supplier/Customer
New Supplier
Both the new supplier and the customer should be on the same page as to what the expected deliverables are. This will establish the basic foundation from which the future relationship will be measured.
Key contacts should be made in the areas of Quality, Engineering, Manufacturing, Purchasing and Customer Service. This will streamline communications and insure the proper parties are aware of key deliverables.
It’s best to create boundary samples to avoid interpretation errors later on. The goal is to eliminate subjectivity as much as possible on both sides (supplier and customer).
If possible, retain the last “acceptable” shot (part and runner attached if applicable) off of each mold prior to transferring. This visual sample will provide key information to the new supplier in terms of current mold condition and customer acceptance standards. Preferably, parts should be untouched as they are molded prior to any secondary operations. This last shot should be inspected by the new supplier and matched against the customer’s current quality acceptance standards for conformance (i.e. all notes, dimensions and cosmetic attributes). Noted deviations will require customer disposition to assure all acceptance documentation matches the approved customer signed off “golden” sample.
Full disclosure is essential in meeting short and long-term goals. This should include past history as well as current status.
Jointly develop an action plan to resolve outstanding problems in accordance with future production needs and in order of importance. This will provide a successful foundation on which to build on.
For another post related to injection molding, check out:
7 Aspects to Identify When Designing Injection Molded Plastic Parts
Are you looking to design, develop, or produce a component that needs to be injection molded to complete the project? Do you know what key aspects you need to identify as you go to design molded plastics?
When going into this process, you need to identify both the obvious and not so obvious! Below are 7 items for you to consider before launching your project.
These are some of the things you must look at when deciding to injection mold a component. The key to a successful project launch is doing the homework up-front during the conception and design stage. Work with your engineering, molding vendor, resin suppliers, and other resources to properly identify and work through all aspects. THIS WILL LEAD TO A TIMELY AND SUCCESSFULLY PRODUCT LAUNCH!
Next, you will need to choose from a wide variety of types of resins. With these resin classes, you have a variety of products that gives you the flexibility to customize your needs. It also allows you to match the resin to the part design and moldability of the part.
In summary, when choosing a plastics resin to use in any type of injection molding applications, the possibilities are limitless. The list above just touches the edges of options for resin selection. By working with a Ferriot, Inc. representative, we will help you identify the correct and optimum resin to use in your applications. We benefit from having long-term partnerships with leaders in resin manufacturing. This allows us to optimize the success of your projects.
For another blog post by Brad, check out:
How Ferriot is Different from Other Plastics Manufacturers
Most engineers do not have ways to attach notes, tolerances, colors, etc. to a 3-D model, so 
they typically use the 2-D drawing to communicate important information. This blog post is an explanation of why 3-D CAD data is used as primary data and why it is critical for 2-D prints to not conflict with the source data.
The arrival of 3-D CAD modeling and direct CNC machining have allowed mold-makers to program the machining of molds directly from the 3-D model. This has significantly helped with saving time and money in both design and machining over old manual efforts in mold construction. Due to these technologies, most tool build times are in the sub-10 weeks range, as opposed to as much as twice that in the not too distant past.
New Technology = New ConsiderationsThese advancements in technology come with some challenges that must be taken into consideration.
Information on the 2-D part drawing cannot be allowed to trump data in the source 3-D model, an approach that is difficult to manage in today’s world because most CAD systems create the drawing from the source 3-D model. Indeed, the 3-D model defines the geometry of the part, but the 2-D part drawing is used to add specific information and notes about the part. Unfortunately these systems may allow for manual dimensional adjustments on the drawing that may not transfer back to the 3-D base model. And that’s where some problems enter: the designer of both the 3-D data and the 2-D print must resolve differences to clearly define to manufacturers what to produce.
Designers recognize the need for tolerances. In most cases, an equal plus and minus allowance is noted for specific dimensions on the 2-D print. In some instances, it was common practice to tolerance only one side of certain feature on a 2-D print. This approach would allow for expected variations in sizes while still allowing parts to fit together as intended – even at the extreme limits of tolerances. However, if the 3-D model were designed using this approach, the resulting mold and part would be built at the extreme limits of the available tolerance, actually making it difficult, if not impossible, to meet the expected tolerance, and certainly would not be able to attain statistical capability. The solution is to design to a nominal size and apply tolerances bi-laterally, thereby allowing tolerances seen in mold-making and injection molding, while still meeting design intent.
Statements like “2-D part drawings supersede 3-D design data” are impractical. When the 3-D design data is used to create the part, it has to be primary. Anything else is putting unreasonable responsibility on others to catch every difference between the two types of part definition.
This is a challenging but critical subject in part design. Because a mold is machined directly from 3-D CAD data, all draft angles and shut-off angles must be fully defined in the 3-D model. Again, notes on a 2-D drawing really aren’t able to be used in the mold build process – unless a mold designer modifies the 3-D part model – potentially a risky idea unless there is careful collaboration between the mold designer and the part designer.
To take full advantage of the technologies available it’s essential to address these challenges. In fact, in today’s world, it is unavoidable – it’s only a question of when. Early in the design stages is far better than if addressed at the start of the mold build, it is time consuming and potentially puts the part design at risk unless mold designers and part designers communicate carefully. Worse yet, if not properly addressed, there may very well be undue challenges in manufacturing, increased costs, and disappointing product performance.
Image courtesty of khunaspix via FreeDigitalPhotos.net
[post_title] => Resolving 3-D Data vs. 2-D Drawings for Part Definition [post_excerpt] => The benefits of using 3-D modeling for spec creation vs. 2-D drawings. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => resolving-3-d-data-vs-2-d-drawings-for-part-definition [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:21 [post_modified_gmt] => 2024-03-11 20:11:21 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-resolving-3-d-data-vs-2-d-drawings-for-part-definition/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [112] => WP_Post Object ( [ID] => 2505 [post_author] => 3 [post_date] => 2014-11-06 16:23:00 [post_date_gmt] => 2014-11-06 21:23:00 [post_content] =>To introduce you to the Ferriot blog, I wanted to give you some insight to the company. As the 
newest employee, I feel that I have set of fresh eyes on who Ferriot is and how they compare to the rest of the industry.
When the opportunity came for me to join Ferriot as a Senior Account Manager, several things convinced me it was the right place for me.
All of the things listed above were what made Ferriot an attractive employer. The vision was both evident and obvious, and I wanted to be part of this future.
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[post_content] => Creating a successful injection molded component requires collaboration and the expertise of a skilled team. One of the most critical aspects of the design for manufacturing (DFM) process is selecting the appropriate resin. Choosing the right injection molding resin not only meets design goals and performance specifications but also aligns with budget constraints. By working closely with injection molding experts, you can engineer a solution that fits your needs perfectly.
Before diving into resin options, it's essential to clearly define the end goals for your product. Once these are set, you can narrow down the best resin choices. Here is an in-depth overview of the 12 steps to help you select the right plastic for your injection molding project:
- Analyze Part Geometry
The size, shape, and wall thickness of the part can significantly impact its moldability. Parts with complex geometries or uneven wall thicknesses might be prone to warping, bowing, or other design issues. Early analysis using tools like Moldflow® software can identify these potential problems and suggest design modifications. For instance, resins like polypropylene (PP) are often used for parts with complex geometries due to their excellent flow properties and low shrinkage.
- Define the Design Goals for the Part
Clarifying the main objectives of injection molding the part is crucial. Are you looking to reduce weight? For example, using lightweight resins like polycarbonate (PC) might be ideal. Are you trying to consolidate an assembly into fewer components or cut costs? High-performance engineering resins like polyamide (nylon) could provide the necessary strength and durability.
- Describe the Key Physical Attributes Required
Understanding how the finished part will be used helps determine the necessary physical attributes. Does the part need high impact resistance, like acrylonitrile butadiene styrene (ABS)? Or perhaps it requires flexibility, where thermoplastic elastomers (TPEs) might be a better fit.
- Describe the Environment in Which the Part Will Be Used
The environmental conditions the part will face can significantly influence resin selection. For example, if the part will be exposed to outdoor conditions, UV-resistant resins like ASA (acrylonitrile styrene acrylate) are ideal. For high-humidity environments, polybutylene terephthalate (PBT) is known for its moisture resistance.
- Regulatory Compliance
Depending on the part's application, it may need to meet specific regulatory standards. For instance, if your product is intended for food contact, FDA-approved resins such as polyethylene (PE) or certain grades of polypropylene (PP) will be required. Similarly, medical devices might need to use biocompatible materials like medical-grade polycarbonate.
- Desired Finished Appearance
The aesthetics of the part can also dictate the resin choice. If you need a high-gloss finish, materials like polycarbonate/acrylonitrile butadiene styrene (PC/ABS) blends work well. For a matte finish or specific texture, other resins can be textured during the molding process. Custom colors and decorative finishes can be achieved with additives and dyes tailored to the selected resin. Don’t forget that the ideal color can also be achieved by painting your parts after molding. It is important to understand cost advantages when comparing the cost of painting a neutral colored part to using colorants or custom compounded resins.
- Identify Chemical Exposure
Chemical exposure during manufacturing, assembly, or end-use can degrade certain plastics. If your part will be in contact with automotive fluids, fuels, or cleaning solvents, a chemically resistant resin like polyoxymethylene (POM), also known as acetal, might be the best choice. For household cleaning products, using polyethylene (PE) or polypropylene (PP) may provide the needed chemical resistance.
- Assess Electrical Requirements
If the part will be subjected to electrical loads, using a resin with good electrical insulating properties is essential. For instance, polyetherimide (PEI) is commonly used for its excellent dielectric properties. If electromagnetic interference (EMI) or radio-frequency interference (RFI) shielding is necessary, resins like polycarbonate (PC) can be combined with conductive fillers.
- Evaluate Radiation Exposure
Parts exposed to radiation, such as UV light or gamma rays, need resins that can withstand such conditions. UV-stabilized resins like ASA are designed to resist discoloration and degradation from sunlight. For applications involving sterilization, resins like polyphenylsulfone (PPSU) can endure gamma radiation without losing mechanical properties. When the desired resin might not be ideal in this situation, painting the molded parts can be a consideration to solve this issue.
- Document Size and Dimensional Tolerances
Accurate dimensions are often critical for the proper function and fit of parts. If tight tolerances are necessary, consider resins with low shrinkage and high dimensional stability, such as polyphenylene oxide (PPO). This resin is known for maintaining its shape and size under various conditions.
- Note the Range of End-Use Temperatures
The resin’s properties can change dramatically with temperature. For instance, if your part will be exposed to both high and low temperatures, polyetheretherketone (PEEK) is an excellent choice due to its wide thermal operating range and excellent mechanical properties.
- Estimate Production Volume
Understanding the number of parts needed helps determine the most cost-effective resin. For high-volume production, cost-efficient resins like polypropylene (PP) or polyethylene (PE) are often preferred. For lower volume, high-performance parts, investing in engineering resins like polycarbonate (PC) or polyamide (nylon) may provide the best balance of cost and performance.
By following these 12 steps, you can make a more informed decision in selecting the right resin for your injection molding project. Each step addresses a critical aspect of the product's performance and the environment it will encounter. Be sure to discuss this with your tooling design engineer to optimize your products.
To further simplify this resin selection process and ensure a smooth transition from design to production, Ferriot has developed an Injection Molding Resin Selection Workbook. Download your free PDF by clicking the button below and start your project off on the right foot.
Get the Resin Workbook!
Have some questions? Just Ask us and we would be pleased connect you with one of our experts to discuss them with you.
[post_title] => 12 Critical Steps for Selecting the Best Injection Molding Resin: A DFM Approach
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[post_content] => When creating custom plastic enclosures, whether for electronics, consumer products, or industrial equipment, the manufacturing process you choose profoundly impacts design requirements. One of the most widely used manufacturing methods for plastic enclosures is injection molding. However, the injection molding process has its considerations that designers must navigate to achieve functional and aesthetically pleasing results.
You may be developing an enclosure for a new consumer electronics device. Or the façade of a new electric vehicle (EV) charging station. Maybe it's next-gen emergency medical equipment used by EMTs and hospitals; it doesn't matter. Ferriot has a great deal of design experience with custom injection molded enclosures. When designing a new product, it is essential to consider several key factors when using an injection molded custom plastic enclosure, regardless of the final application.
The Ferriot team has years of experience in the custom injection molding industry. Logically, tapping their knowledge and expertise in new enclosure development makes sense. This article provides valuable insights into successfully completing your new enclosure design while balancing form and function.
Design considerations for custom injection molded enclosure design include wall thickness, ribs and reinforcements, corners and fillets, and undercuts
Considerations for New Custom Plastic Enclosure Design
The User Experience
Critical to the success of any new product is having a thorough understanding of how the user interfaces with the enclosure, the mating components used during assembly, how all the pieces and parts fit together, and how much interference or clearance exists in those areas.
If the equipment is to be serviced or maintained, the designers must determine where access to interior components is needed. This data enables the team to start thinking about the necessary tolerances and if there are areas of risk. Sometimes, the product designer needs to be sure of how things will work, or even if it will work, within the current design. Then, the team reviews the option of building prototypes to test these unknowns, especially for any risky areas. Prototyping is always a good idea to test the feasibility of the design before going too far.
Design for Manufacturing (DFM)
Tooling engineers will utilize your product design and inputs to design tooling to manufacture your enclosure. To optimize production and part quality, the tooling engineer must consider several design features for the mold, from gate placement to surface finish.
Gate Placement: Where It All Begins
The gate, the entry point for molten plastic, is pivotal in how material flows into the mold cavity. Gate placement is more than just a technical consideration—it affects material wastage, defect potential, and the part's visual appeal.
Defining gate placement in the custom injection mold design
Wall Thickness: The Key to Structural Integrity
Uniform wall thickness is a cornerstone of successful injection molding. It ensures even cooling and reduces the risk of defects such as warping and sink marks. Maintaining consistent wall thickness throughout the enclosure ensures structural integrity and contributes to a polished final product.
Strength in Ribs and Reinforcements
Enhancing the plastic enclosures' strength without compromising material usage is a challenge that can be addressed through thoughtful rib and gusset placement. By strategically adding ribs to specific areas of the enclosure, designers can prevent flexing, warping, and deformation, all while optimizing material distribution.
Smooth Corners and Fillets for Durability
Sharp corners might look sleek, but they often lead to stress concentration points and potential cracks. To mitigate these issues, incorporating rounded corners and fillets boosts part strength and reduces the risk of defects during molding.
Navigating Undercuts and Complex Features
Undercuts, or features that prevent part ejection, can complicate the mold design. Addressing undercuts effectively or designing them to be mold-friendly is a strategy that simplifies tooling and minimizes costs. This balance between complexity and manufacturability is vital.
Surface Finish and Texture: Practical and Aesthetic Impacts
The texture of the mold's surface transfers to the final part. Designers have the freedom to choose from an array of surface textures, but they must carefully weigh how these textures influence aesthetics, grip, and part release.
Material Selection: A Delicate Equation
Choosing the right plastic resin is crucial. In addition to necessary properties such fire or chemical resistance, one must understand how the resin reacts to the molding process. Different materials exhibit varying shrinkage rates during cooling and solidification. Designers must select materials compatible with the injection molding process and account for this shrinkage when determining dimensions. It is crucial to start the resin material selection process based on the standards and compliances your product must meet.
Material selection requires multiple considerations
One example: If you're designing a medical device that needs to be near or in an MRI machine, it cannot have any metal whatsoever in the enclosure, including any metal inserts. That could be very dangerous inside an MRI machine.
An additional consideration when designing a medical device enclosure is the importance of EMI/RFI shielding. Design engineers must take care to ensure that their device doesn’t emit signals and that it meets various EMI-RFI shielding standards. If reducing RFI through design isn’t possible, engineers can use an RFI-shielded enclosure as an effective solution.
RFI shielding can be applied internally to electronic enclosures as a spray. This coating spray is often used in plastic enclosures to reduce interference effects. (See Understanding EMI / RFI Shielding for Injection Molded Components to learn more.)
EMI/RFI shielding application to custom injection molded part
Once you have narrowed the resin selection, Ferriot’s supply chain team can work with you to determine its availability. The purchasing team researches where the materials are readily available, finding the best combination of price and delivery. We work hard to find the best possible price for the best quality materials that meet the enclosure's design criteria. It helps narrow the material selection, so we provide a list of the appropriate materials and let you, as the customer, make the final decision.
Striking the Balance of Mold Complexity
Complex molds with intricate features might unlock design possibilities but also increase tooling costs and production time. Striking the right balance between design complexity and manufacturability is critical to ensure feasibility and cost-effectiveness.
Integration of Assemblies: Beyond the Mold
A well-designed enclosure isn't just about what comes out of the mold. Designers should evaluate how different enclosure components fit together and how they can efficiently assemble them post-molding. Considerations include features like snap-fits, screw bosses, and alignment guides.
Tolerances: The Fine Print of Design
Though injection molding is extremely precise, it is necessary to account for variations in material shrinkage, mold wear and other factors during the manufacturing process that affect part size. Design and quality teams will determine acceptable tolerances which define the acceptable size variations for certain part features and overall dimensions. Tolerances allow for variation while ensuring that the part will still function and mate with other parts.
The Role of Moldability Analysis
Harnessing the power of computer-aided design (CAD) software to conduct moldability analyses is a smart move. This process identifies potential issues early on, allowing for necessary adjustments before the costly tooling stage.
FDA Requirements for Medical Devices
Understanding the FDA requirements for medical equipment is imperative to help decide the correct material selection and design controls. Then, knowing the product requirements, UL, flammability ratings, impact testing, and chemical and UV resistance is next. The product designer must prioritize these requirements, so the custom injection molder knows the most important ones. Then, our manufacturing engineering team will focus on hitting those requirements.
Summary
As you can see, developing a new enclosure requires much consideration. Designing plastic enclosures for injection molding is a delicate balance between aesthetics, functionality, and manufacturing feasibility. The considerations outlined are essential guideposts that steer designers toward creating enclosures that look great and result in efficient production using injection molding. Collaboration between designers, engineers, and manufacturers is the key to unlocking the full potential of this manufacturing process while delivering exceptional products to end-users.
The Ferriot team is here to support you in developing the right enclosure design that provides the proper form, fit, and functionality in a highly durable and attractive package. Based on the part geometry, complexity, and numerous other design factors, we work closely with you to develop the best custom injection molded solution for your new product’s design.
Learn more:
Want to learn more about metal to plastic conversions? Discover how we tackled complex challenges when a fuel pump original equipment manufacturer (OEM) was seeking savings through a durable plastic conversion here.
[post_title] => Benefits of Replacing Metal with Plastic
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[post_content] => Customers often ask us, can you paint plastic molded parts? The answer is yes, although painting molded plastic requires specialized knowledge, the proper equipment and an experienced staff. Special paints are required to give your parts the desired finish and ensure the paint bonds well with the plastic. However, painting techniques have evolved over the years and there are several different means by which the plastic parts can be painted to meet any need.
Molded plastic is typically painted using a multi-step process that involves surface preparation, primer application and topcoat painting. The plastic surface is cleaned and treated to ensure paint adhesion, followed by a primer application. Finally, the desired topcoat paint is applied in layers, before curing. Curing creates a durable, attractive finish.
There are two main reasons why painting molded parts provides a benefit to the customer:
Example 5-color digital printing on custom injection molded medical enclosureDigital printing allows for unlimited color options (Source: Engineered Printing Solutions)Example of digital printing on larger injection molded parts (Source: Engineered Printing Solutions)Due to digital printing’s large print area, it is possible to print on multiple parts simultaneously (Source: Engineered Printing Solutions)
To try to produce this one 28-gram part out of this large tool, with plastic that sits in the barrel for hours and hours, it's just not possible to do. So, we learned the hard way that we could only produce this part within spec by sacrificing a larger part to get the proper material flow into the tool we needed. And that raised the price of this part from approximately $2 to $10, which our customer was not happy about.
Liz: Are there common shortcuts that mold makers take that our customers should be aware of that, "Hey, be careful if somebody says, 'We're going to do it this way,' because this can get you into trouble or can cause a problem in the future"?
Amy: Well, there's just a lot of unknowns until we receive the transferred tool. We request drawings or 3D models of the tool in advance. However, we always need to find out if we're getting the most updated version of that tool's drawings and models. It's common for the tool design not to be updated as the part design gets updated. So, we only know what we have once it gets here at Ferriot.
Liz: Really? The physical tooling could have been changed, and the spec drawings or whatever were not changed to reflect that?
Amy: Absolutely. It can be a revision control nightmare.
Liz: What is the most common reason a mold owner would arrange to transfer their mold tooling?
Amy: We often don't know. The mold owners often don't want to be transparent with us about the problems they're having with their current supplier. They're either experiencing quality issues, delivery issues, costing issues, or a combination.
Jerry: Agreed. It's usually because either the customer is having trouble with their current supplier's quality, delivery, or something else, or the current supplier just has told them they want to get rid of it. One of the parties is having trouble and needs to move the tool.
Liz: What are some reasons the current supplier would want to get rid of it? Slow-paying customers, things like that?
Amy: Low volume orders, price issues, or too much scrap.
Liz: We've also done that, where we've told customers to take their tools elsewhere. Many times, these might be legacy customers moving on to new products and suppliers, and we're being used to produce service parts for the old products. We've lost the business, and it's not worth our effort to continue to run small orders for them, and it's ending a business relationship.
Who are the key players on our Mold Tool Transfer Team? Then, beyond the project manager, who do you typically work with on the customer side?
Jerry: It works best to involve the customer's project manager, product engineer, and quality engineer. We need the complete history of the tool, how it's designed, and the product requirements. It doesn't work well when the only person involved on the client side is the purchasing procurement people. They tend to know little about the tool, the part, or anything else; they're just trying to get the business transferred. Period. And they don't know anything technical about the tool, nor do they know much of anything about the finished part.
Amy: Optimally, our team typically includes the project manager, tooling manager, quality manager, and a process engineer. That is ideal.
Liz: A great deal of these processes’ hinges on good communication. There are also a lot of details that need to be reviewed, revised or even replaced with process improvements. It's a lot of servicing the business relationship.
Jerry: Absolutely. Another excellent example of a tool transfer that went well is the tool that came from Swaco. Amy would agree with me. It was a lot of work and effort, but we had all those people pretty much in alignment. We had their process engineer; we had their support from their engineering and quality organization. We knew what we were getting—no hidden problems. We could talk back and forth many times to get the tool up and running. It went very well, and we have a profitable product that we're able to ship them parts.
Amy: That is a good example, Jerry. Initially, there were some growing pains, but you're right; the customer was very supportive. They have injection presses of their own, so they're very familiar with injection molding, which helps tremendously. They were willing to come on-site and help us evaluate the first production parts. They've been very good to work with because they have molding experience.
Liz: Were you guys involved more on the front end before the decision in this case? Or was it just good to have those people helping you after the decision was made?
Jerry: There was good front-end support when we were quoting the receipt of the tools. So, we had a reasonably good idea of what we were getting. But then, to Amy's point, what helped was, when the tool came, we had access to their process engineer, product engineer, and quality engineer. And we worked as a team to get it up and to run and resolve the issue. There was no shortage of work to do and no shortage of effort, but it all went very well because it was a team effort.
Jerry: On other transfers, the buyer arranges them.
Liz: I can see it is difficult because if you're getting a tool from another injection molder, they're either happy to see it go, or they're not happy to see the business go. As a result, you don't necessarily have access to the necessary assistance either way.
Amy: Definitely. It's a tricky business for customers to get information from their supplier that they've never asked for before, like mold designs, process sheets, and things like that. That throws up some flags with their current suppliers, and it sure would if it was asked of us. And there can be a reluctance to share that information for whatever reason.
Liz: Is it a suggested best practice for OEM mold owners to request that information from a molder when they start doing business and setting up new tooling as a form of risk mitigation?
Jerry: I think it's typical. If our customer asked us to provide the mold design, we certainly would do that because they own it. There's no question about it. If we built them a mold, they would own it. We provide them with the design, the 3D CAD, and everything if they want it. However, providing the process sheets, that's different. We'd have to think about that. How important is the customer? That is proprietary information to us. That's how we run that tool. But we'd likely ultimately provide it, especially to a large important customer who understands molding operations.
Liz: Yeah. I could see a company; even if they're going to stick it in a file somewhere, it's just part of owning the tool and mitigating risk just to have the information.
Jerry: Correct. We sometimes run into a problem when a customer is transferring tools to us. If they have it at a different molder, they're sometimes reticent to get the mold design and process information from their current supplier because that would be tipping their hand that they're just about to move that mold.
Summary
Mold tool transfer projects can pose unique challenges, with one of the main difficulties being the unknowns that come with receiving a transferred tool. While OEM mold owners can request drawings and 3D models in advance, there is no guarantee that they will receive the most updated version of a tool's design over time. This issue can lead to problems with producing parts within spec, as well as revision control nightmares. Good communication is critical, and it is essential to have a team involved from both the mold owner's and supplier's sides, including project managers, product engineers, and quality managers, to mitigate these risks.
In part three of this article, I’ll review a few additional mold tool transfer success stories with our team of experts. We will discuss some challenges that we faced with our customers, how we addressed those challenges, and the end results that Ferriot’s solutions team delivered.
To learn more about mold transfer considerations, download the "Mastering the Shift: 7 Key Points for Smooth Injection Molding Supplier Transitions“ white paper.
[post_title] => ShopTALK: Mold Transfer Considerations Everyone Should Know
[post_excerpt] => At Ferriot, we’ve identified seven key points you should consider before making a tool transfer, including everything from inventory to cosmetic standards.
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[post_content] => Mold transfer, beginning with the RFQ phase of the tool transfer inquiry, sharing full transparency throughout the transfer process for efficient and effective tool transfer with your new custom injection molding supplier is essential. Therefore, it is necessary to clearly define the project scope and the responsibilities and expectations of everyone involved.
Before moving forward with production, any tool refurbishments should be quoted and submitted for approval. The required validation processes and protocols should be defined and agreed upon prior to execution by the supplier.
[post_title] => Are you ready for your mold transfer? Tool Transfer Success Checklist
[post_excerpt] => Providing complete and accurate information for your mold transfer helps assure the smooth, timely, and cost-effective transition. Here's what you need.
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[post_content] => Making the decision to move injection molds from one supplier to another can be a daunting task, not for the faint of heart. The saying “the devil is in the details” is very apropos to the mold tool transferring process. If you don’t cover all the necessary details, you may be jumping from the frying pan into the fire. At Ferriot, we’ve identified seven key points you should consider before making a tool transfer, including everything from inventory to cosmetic standards. It takes communication, transparency, precision, and above all, experience. We hope these recommendations help you with a successful transition.
Before we proceed with our ShopTALK discussion, we recommend reviewing our whitepaper Mastering the Shift: 7 Key Points for Smooth Injection Molding Supplier Transitions. Our conversation with Jerry Graf and Amy Mathia will investigate some of these considerations.
Jerry Graf is the Manager of Engineering. Previously, we spoke with Jerry about how mold flow analysis and tool design impact injection molded part quality. Discussing mold tool transfer considerations is a natural extension to that conversation.
Amy Mathia has been with Ferriot for over seven years as an Engineering Project Manager who works closely with the customers, our tooling engineers, and the production department on new product development. One of Amy's main goals is ensuring projects are within budget, and her experience includes some rather challenging mold tool transfers.
Liz: In addition to the white paper that I mentioned earlier, how does Ferriot help customers feel comfortable that, when they transfer their mold to us, we can hit the ground running?
Jerry: We use a checklist, a guide for transferring tools. Engineering also has an internal checklist that we would go through upon receipt of the tool to ensure it is clean, properly maintained, and ready for our production floor. It's very similar to the checklist we would go through when we receive a new tool we built or had built for us. With the checklist, a prospect can go down the list and say, "Yeah, okay, I've got all of this lined up, so I now can proceed with a higher degree of confidence.”
Liz: Why might a mold owner want to stay with their current supplier?
Amy: As we’ve learned about tooling problems, quality issues, and so on, we had to tell prospective customers, "Here are some of the headaches you're going to have." We don’t sugarcoat it because it can become expensive to correct these problems.
Jerry: And it can go both ways. Because on the saes side, we're interested in earning more transfer business, but on the engineering side, it (often) creates many, many headaches for us. So, when talking to a potential customer about clear and obvious issues, we must ask them, "why would they want to do it? Is it worth it? Why should they not want to do it? What are the options?
Liz: So, it is important to know ALL the “why’s” when it comes to a pending transfer?
Jerry: Yes, that is one of the critical questions. Making sure we're talking about some of the (possible) headaches, one of the key questions to ask when taking on a transfer tool is, "Why are you transferring it?" More often than not, it's because they're having trouble with it.
Liz: And what kind of trouble are they having?
Jerry: Frankly, if a customer transfers the trouble, that's moving it to a different spot; it isn't solving the problem. So, we need to have a frank, open, and honest discussion about what is wrong. Why are you (really) transferring it? Why do you want to transfer it?
Liz: After you find that out, do you ever say, "Well, you probably shouldn't transfer because we may not have the answer for you." Or do you confer amongst the engineers at Ferriot for a solution?
Jerry: After assessing the situation, once we know the problem or problems, we often tell them, "Well, yeah, we can help you with that. We can help resolve that situation. And here's what getting this mold into the proper shape will cost."
Another bad reason to move it is that the tool is old and worn out, and your current supplier can't provide quality and can't maintain production. But if the tool is old and worn out, neither can we. If there's something wrong with the tools, that must be taken into consideration either before it's transferred or as it's being transferred.
Liz: What are some good reasons to do a mold tool transfer?
Jerry: A good reason for moving a tool would be you're moving it for logistical reasons. For example, you're getting it closer to where it needs to be from a manufacturing or distribution perspective, so you're not shipping the finished product so far. Or you're moving it to a supplier with superior capabilities to run the part.
Amy: To be perfectly honest, I'm not a big fan of transfer tooling. It's okay to be blunt about it. Typically, the reason is it's a problem somewhere else, and our customers want to move that problem. And when our biggest customers ask us if they can do that, we can't say no. However, one of the best reasons I have heard of in my experience for moving tools to Ferriot would be the value-added things we can do here—for example, painting parts. If a mold owner has a part being molded by another supplier, and then they must send the parts somewhere else to get painted, additional costs are obviously involved. So, one good reason for transferring to Ferriot is that we also print and paint parts. Those are just two of the value-added things that we do. But in general, when someone is looking to transfer tooling, it's a problem somewhere. Tools aren't being moved because everything is running beautifully. It just doesn't happen that way.
Liz: Yeah. Like Jerry said earlier, they're just looking to move the problem and that's not always a solution. However, we can work with them to find a solution.
Amy: Absolutely. Another thing that could be a good and a bad reason is capacity. Your current molder might not have the capacity, and you might find a molder that has the capacity and can speed up your lead times.
Jerry: Yes. That would be another good reason to move the tool. It is a reason that would not be necessarily problematic if you're looking for a supplier that has additional capacity, additional capabilities of any sort, as Amy mentioned, finishing capabilities, capacity capabilities, maybe some processes that your current supplier doesn't have because they're more of a shoot-and-ship shop. And just trying to consolidate that all in one place. Those are reasonable reasons to want to move the tool.
Liz: With the recent increases in fuel costs, are you seeing people interested in transferring molds because of the shipping costs?
Jerry: Yes. We're seeing customers bringing tools here from Asia because of the problems of getting parts across the ocean. They're re-shoring some tools into North America.
In part two of this article, I’ll review addition tool transfer considerations as well as a few mold tool transfer success stories with our team of experts. We will discuss some challenges that we faced with our customers, how we addressed those challenges, and the end results that Ferriot’s solutions delivered.
[post_title] => ShopTALK: Mold Transfer Considerations Everyone Should Know [post_excerpt] => At Ferriot, we’ve identified seven key points you should consider before making a tool transfer, including everything from inventory to cosmetic standards. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => mold-transfer-considerations-everyone-should-know [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:08 [post_modified_gmt] => 2024-03-11 20:11:08 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-mold-transfer-considerations-everyone-should-know/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [16] => WP_Post Object ( [ID] => 2260 [post_author] => 3 [post_date] => 2023-07-14 13:00:00 [post_date_gmt] => 2023-07-14 18:00:00 [post_content] =>
In our previous article, Is it Time to Break Up with Your Custom Injection Molder?, we addressed missing deadlines, cost overruns, and quality issues as three primary reasons for deciding to move to a new supplier by transferring your mold tools.
However, before making such a significant leap of faith, you must be careful not to jump from the frying pan into the fire. As a first step, take time to understand the "Mastering the Shift: 7 Key Points for Smooth Injection Molding Supplier Transitions."
While it seems common sense that the most critical key to success is maintaining complete transparency throughout the transfer process, it is surprising how many times that does not happen. Understandably, to accomplish that level of transparency, open and honest communications must exist between the mold owner and the potential new supplier. The harsh reality is that, sometimes, the mold owner can be the source of their headaches through miscommunications and "errors of omission" (intentional or unintentional).
At Ferriot, we have been managing mold tool transfers for many years and pride ourselves in meeting and exceeding client expectations when we deliver finished parts to these clients. However, we've had some mold tool transfer challenges over the years and experienced several things that cause mold transfers to not work out so well. We know that if a customer wants to move a mold to us, it is usually not for a good reason.
Reasons can include:
Ultimately, everyone looking to transfer a mold wants to be completely satisfied with their finished product in every way, but for some reason, they are not. That's why we're here. Being open about any existing mold tooling problems and understanding the need to invest in corrections or improvement are two things that cannot be ignored.
Many problems begin when the company transferring the mold is unwilling to invest the money necessary to make the necessary corrections or improvements.
However, as is the case with most business challenges, the problems are rarely one-sided. For example, ask any custom injection molded parts customer whether they have had issues with a molder, and they laugh at the thought. Some may even respond, "Too many!"
Despite the issues, for many mold owners, even the thought of moving work is a tremendous pain, and there are numerous reasons to avoid it. For example, forecasting the current and near-term demand and then building a bank while keeping it from the current molder. Then, there's paying to move the tool, hoping it is not damaged in transit. Assuming the tool makes it successfully in one piece to the supplier, there are the costs and time associated with requalifying parts at the new supplier. Some decide, "Maybe it's better to stay with the devil I know than move things to the devil I don't."
At Ferriot, we understand these concerns, and our Mold Tool Transfer Team works very hard at maintaining transparency and keeping the lines of communication open, knowing that the devil is, in fact, in the details. More and more mold owners have learned that transferring their molded parts requirements to us is wise; we specialize in highly engineered custom parts with highly engineered resin. In our tenth decade, experience has taught us the accurate and fair cost of providing parts to customers on time and to exact specifications.
And that brings us to the biggest headache: After all the time and effort, some companies look at the tooling and piece part price only. Awarding work this way can be a mistake. Understanding the lifetime value of the tool is important as well as the details on how the molder came to their pricing. Also once you have selected your molder, the DFM phase is where some part redesign will more than likely be needed. Collaboration with a team you can work well with is key. The most important work is done up front and will save money in the long run.
However, we know that will be the first and not the last we hear from many mold owners. They eventually realize their mistake, and after tens of thousands of dollars and tons of angst after a year or so, they call us to help fix it.
Ferriot can fix it, but if you want to save money and hassle, trust us up-front. Or trust us later.
[post_title] => Headaches to avoid when transferring a mold to a new injection molder
[post_excerpt] => Before working with a mold tool transfer company, here are a few headaches to avoid.
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[post_content] => Injection molding is a widely used manufacturing process that produces plastic parts in high volume. Multiple industries rely on this process, including medical, electronics, automotive, agricultural and consumer products, to name a few. This highly efficient manufacturing method has a projected CAGR of 5.1% through 2027, for a potential market value of $240.9 billion.
During injection molding, molten plastic material is injected into a mold cavity, allowing it to cool and solidify. When cooled, the parts are ejected. However, certain manufacturers new to the process might cool to the idea of injection molding after investigating the startup costs.
A careful examination of key phases of this process can help manufacturers more successfully navigate this cost challenge. These can include the total cost of ownership, the importance of resin selection during the planning phase, design for manufacturability and secondary operations. This examination can help determine whether injection molding is a viable alternative for a new project proposal and will supply the desired return on investment.
Total cost of ownership (TCO) represents a crucial metric in manufacturing that considers all the expenses associated with a product or part over its entire life cycle. For injection molding processes, TCO includes costs such as the price of the mold or tooling costs, the cost of the particular resin specified for the part, and the average cost of manufacturing as a price per piece basis over the projected product lifecycle.
The cost of the mold can be significant, and it is essential to consider its expected lifespan and the volume of parts it can produce, to calculate its actual cost. The price per piece is calculated using factors such as the material used, the part complexity, the number of units produced per run and the setup costs associated with each individual run.
Finally, resin costs can represent up to 50% of the total part cost. Resin choice impacts a variety of factors per project. For example, when the part is required to withstand exposure to UV rays or needs chemical resistance capabilities, this will restrict resin choices to thermoplastics that offer these characteristics.
The higher cost of setup and tooling associated with injection molding compared to other plastic technologies often restricts the process to companies that make parts with larger volumes, from the thousands to the millions. Certain specialty parts in smaller quantities that meet a specific market need also take advantage of injection molding. Tooling, resin selection, part quantities and overall volume over the course of two to three years can supply manufacturers with a reasonable expectation for total cost of ownership to compare pricing.
When it comes to selecting the right resin for injection molding, there might not be a more crucial factor impacting the project cost. The resin itself often dictates conditions of tooling or mold making. Molds are constructed according to mold flow analysis of the resin choices and desired properties. Once this mold flow analysis is conducted and the tooling created, its performance is linked to the specific resin analyzed for that mold.
Factors involved in resin selection will include the material’s:
For example, when producing injection molded parts destined for use on gasoline dispensers and pumps, the resin must exhibit a high resistance to the chemicals present in gasoline.
Resin costs typically account for approximately 50% of the total project cost. Prior to making the mold or tooling, companies new to injection molding can consult with the engineers at an experienced partner such as Ferriot, to discuss resin alternatives based on the properties desired in the finished product.
Engineered resins can cost as much as $10.00 per pound or more, while lower-cost commodity resins like PVC, polypropylene, or high-density polyethylene can be less expensive. The best time to determine resin options is early in the planning stages.
Part of resin selection is also looking at resin availability, location of the producer and/or distributor(s) and lead time. Resins that are more widely used pose less supply chain risk. One might consider supply agreements for highly specialized resins or blends. It is also suggested to qualify more than one resin in the tool as a backup to provide insurance against any future supply issues.
The cost of tooling is a critical factor in the injection molding process and can vary widely depending on the size and complexity of the mold. While purchasing tooling from vendors in the Pacific Rim may offer cost savings, manufacturers also need to consider all factors involved with ordering tooling from overseas.
There is typically a longer transit time for overseas tooling that can stretch from eight to twelve weeks for oceanic shipping. Some customers will cover the cost of air freight to reduce lead times, although this adds to the expense.
There are additional concerns about intellectual property being compromised, particularly when dealing with vendors located in countries like China, Vietnam, or Korea.
Alternatively, tools made in North America, particularly in the US and Canada, are more expensive but offer a quicker turnaround time and greater assurance that intellectual property rights will be protected. Companies in highly competitive markets where proprietary business practices weigh more heavily, such as medical instrumentation, electronics and semiconductors for example, are most concerned about protecting intellectual property. Manufacturers must carefully weigh these factors when considering the cost of tooling and where that tooling is created, for risk mitigation and as part of total cost of ownership.
The cost of the mold is one of the biggest barriers for market entry for some startup companies. Someone new to injection molding might not be aware that the mold can cost anywhere from $30,000 to more than $600,000 depending on the size.
Another design option to lower costs over time for projects with large production runs is to consider a multi-cavity tool. This allows multiple parts to be produced at a given time. The initial cost of a multi-cavity mold might be higher than a single cavity; however, this can be amortized over the mold's life.
After the tooling, when creating or producing a product run, there are the injection molding machine cost which includes utilities, labor and setup. This typically comprises 30% of a project cost. The setup is a fixed cost and remains the same regardless of whether a customer produces one or one thousand parts.
Additionally, the production lot quantity is another cost bucket, which refers to the total quantity of parts produced in a single production run. Ferriot often runs on a 60-day cycle, producing the quantity required by a company for that time period. This balances the setup costs and labor with warehousing and storage.
The size of the production run can help amortize the setup costs, or the labor involved in installing the mold into the press. Certain molds might take an entire day to set up. In other cases, a heavy mold of 40,000 pounds for example, might require an overhead crane to move into position. Mold set up requires time and takes an experienced, sophisticated team.
A better understanding of these cost components can help manufacturers make well informed decisions to optimize production and reduce costs.
One of the key advantages of working with Ferriot is its ability to offer a wide range of finishing operations all under one roof. This reduces the complexity of the supply chain for customers that might otherwise need to ship parts to multiple locations for services such as painting, pad printing, or the insertion of metal components.
Ferriot has built a reputation in the industry for these services and most customers take advantage of these finishing operations. A comprehensive approach to plastic part fabrication can help save customers time and money by streamlining the production process.
The engineering team at Ferriot is also available to consult on design for manufacturing (DFM). Typically, the customer will specify a resin preference according to the design brought into the shop. On occasion, the part’s design will not suit the injection molding process. The Ferriot team can supply suggestions for design modifications when drafts or undercuts might limit the ability of the part for injection molding.
Companies of all sizes trust Ferriot for injection molding and value-added finishing services. The company makes every effort to overcome supply chain issues by leveraging its relationships with multiple suppliers. By investing in spare parts to keep machinery in top working order and increasing its stock of resin, Ferriot can help customers maintain project timelines. Call Ferriot today to discuss your next injection molding project.
[post_title] => Navigating the Cost of Injection Molding: Factors to Consider [post_excerpt] => An examination of key phases of injection molding can help determine whether injection molding it's a viable alternative for a new project proposal and will supply the desired return on investment. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => navigating-the-cost-of-injection-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:08 [post_modified_gmt] => 2024-03-11 20:11:08 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-navigating-the-cost-of-injection-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [18] => WP_Post Object ( [ID] => 2262 [post_author] => 3 [post_date] => 2023-03-01 15:16:00 [post_date_gmt] => 2023-03-01 20:16:00 [post_content] =>
Problem: Ferriot needed to find a way to produce a high-mix, low-volume portfolio of parts for its customers without requiring two or more operators on every job.
Solution: The combination of cobots and vision systems was quickly adapted to handle a wide range of custom injection molded parts.
Dave Tillett, editor at Plastics Machinery Magazine, in a recent interview with Jeff Hodnick, an automation engineer at Ferriot, learned how Ferriot turned the problem into an opportunity and ultimately developed their solution.
By using cobots in coordination with vision systems, Ferriot can handle tasks that formerly required human operations to perform mundane tasks repeatedly. After implementing its new automation processes a few years ago, Ferriot can better utilize its workforce more efficiently to perform essential tasks, resulting in better quality control and efficient expediting of deliveries.
Ferriot is putting cobots into service in some very unique ways. “The easiest task for a cobot is pick-and-place stuff,” Hodnick said. “From there, it kind of evolves up into where we actually put Dremel tools to use a cobot almost like a CNC. Worked phenomenal, too.”
Ultrasonic welding is another job the automation department tackled. “We use parts underneath an ultrasonic welder with one cobot. We had to come up with some of our own proprietary stuff to pull it off, but we were able to.”
Read the full article from Plastics Machinery Magazine to learn more.
Learn more:Automating Injection Molding Processes Improves Efficiency: Cobots & Vision Systems
Automating Injection Molding Processes Improves Efficiency: 3D Printing End-of-Arm Tooling
Ultrasonic Welding: What Designers Need to Know
Importance of TQM to Injection Molding Projects
In our last article, I spoke with Jeff Hodnick, our Automation Engineer, about how Ferriot is integrating new automation technologies, such as 3D printing and custom end-of-arm tooling design. Previously, we outlined how Ferriot utilizes cobots to enable more efficient manufacturing in injection molding.
In this installment, Jeff shares additional details on how Ferriot uses the latest cobots and vision systems to strategically enhance the Ferriot workforce while increasing throughput and assuring quality.
Liz: A few years ago, we wrote about how Ferriot used our new cobots in manufacturing. Since then, you've been utilizing them even more. How are you using them lately? What are some of the things our people can now do instead of the processes the cobots are taking care of?
Jeff: So right now, we have one that does some of the dual plastic-on-plastic welding out in our molding department. And then we also have another one where we rotated between an ultrasonic welder and a pad printer back in our finishing department.
In all three use cases, it's allowed us to take what would be a two-to-three-operator job and bring it down to one. Plus, we have our insert welder on a cobot. Using that approach, we can weld and move the part around approximately three times faster than a typical human operator—without the fatigue a person would experience. As a result, the new approach frees up space and at least one person on everything we deploy to the cobot.
We're in the process of evaluating the addition of two more cobots to our operations. I'm working on the justifications and planning out the required first deployment steps.
Liz: Since you're looking into more, how much has the cobot technology changed since you bought the first two?
Jeff: Technology has continued to move forward and become more sophisticated. More than anything, they've become even more reliable. There are more options from which to choose. We're evaluating several different brands; most have auto-synchronizing features. For us, rapid deployment, changing molds all the time, being able to quickly move a robot right in front of a belt and synchronize all the accesses and be able to deploy it within 20 to 30 minutes is huge. I've been to the Automate Show in Detroit, which is the largest robotics and automation show in North America. As far as technology changes, we are seeing more reliability and flexibility. All the cobot technologies are making significant strides. Everything is so much more reliable. Conversely, I wish I could say it was easier to get spare parts, but we all know how supply chain issues are right now.
Liz: What are some of the other benefits of cobots?
Jeff: One of the most significant benefits is protection and shielding requirements are minimal. You don't necessarily have to build a large cage around them. Don't misunderstand. You still have to put up some protection whenever you're using cutters, grinders, and stuff like that, in conjunction with them. But, for the most part, they're pretty hands-off. The second they touch anything else that they're not supposed to, they stop almost right away. They're outstanding about all that. There's a whole lot more intelligence there than there used to be.
Liz: When it comes to the companies that make the cobots, they tend to tout the value prop that your people can do something else, and that's kind of vague. Let's be specific. At Ferriot, what can our people do instead because the cobots are now performing these functions?
Jeff: Primarily, we can simultaneously have more active presses because, instead of needing two or three operators dedicated to a single press to run a job, you only need one. This approach results in better labor dispersion, where we can run more presses since we have the people to run them, and we can better deploy our people to the most active, time-sensitive projects. This provides great cost improvements due to lower labor overhead and allows us to help our customers save on part cost.
Additionally, I'm working on a project with the two new cobots I mentioned earlier where we'd be able to have them handle a lot of parts processing. So, all we need people to do is walk between presses and handle packing the parts.
In cases where we're doing all the post-processing with the robot, we classify it as half an operator because the operator doesn't have to wait an hour for parts to be processed. They can split their time between two to three presses at once, packing the parts once they reach a certain quantity at each of the presses. So, it improves our efficiency and labor dispersion.
Liz: How are we using the vision systems along with the cobots?
Jeff: The vision systems are another technology that, while they've always been around, the ease of programming and implementation has recently improved in the last few years. Today, these systems are much more flexible, and easier to use. While we have three systems, we actively use two as part of our quality control.
Imagine a part that takes a hundred (or more) inserts, and because there's such a low volume run, we can't automate it. As a result, sometimes an insert or two isn't put in place properly. In situations like that, we have a vision system that'll check both sides of a part.
We have smaller vision systems that have hot-swappable nests. So, you can use the same exact system, switch between programs and check for a multitude of parts simultaneously. Being able to universally adapt vision systems has been a huge win for us.
Liz: How were those processes handled before having the vision systems?
Jeff: They were mostly manual, dependent on our quality inspectors, Very time and labor-intensive.
Liz: And so, with the use of the vision systems again, like the cobots, those people that used to do those labor-intensive jobs that took a more extended period of time, what are they now doing?
Jeff: Again, it's about strategically dispersing the personnel. We have those vision systems in our finishing department. So instead of only running one or two different parts to that department a day, we're currently running four to five different parts—with different things being worked on widely across it—and sometimes it's even more than that. Our wider dispersion of labor, enhanced with an automation workforce, enables us to get more done, more accurately, with greater throughput and quality assurance.
Liz: In summary, what the cobots and vision systems do for our customers is they bring that consistency that no matter how hard a human being tries, they just can't do. At some point, the human operator gets fatigued.
Jeff: Exactly. The robot sub stand eliminates that issue while saving time. We even have instances where we've put vision systems and inspection systems on the end of a cobot.
Liz: How does that work?
Jeff: We created a custom end-of-arm instead of the normal extruded aluminum. We made it out of a solid piece of aluminum, but we were able to mount a couple different sensors and wire them that way. By doing that, we were able to create a tray where an operator sets a part and then presses a button. A button is only required when we need to ensure the operator is out of the way. Once they hit the button, the robot will individually check for each insert, it'll check depth gauges in key areas, making sure everything is in the correct positions. The robot extends over top of the entire part, completing the whole inspection.
An example is retail fueling dispenser bezels. We’re using the robot and vision system combination for inspection. Basically, the operator sets the bezel, also called the front housing, onto the fixture. Then the robot goes through and inspects each part of it, making sure everything is in correctly. There are secondary sensors as well.
Automation using cobots and vision systems are tools Ferriot uses to streamline processes which improve productivity and save labor overhead cost. These efforts ultimately help to minimize part cost and improve throughput.
[post_title] => Automating Injection Molding Processes Improves Efficiency Part 2 [post_excerpt] => Cobots & Vision Systems for Custom Injection Molded Parts [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => automating-injection-molding-processes-improves-efficiency-part-2 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:08 [post_modified_gmt] => 2024-03-11 20:11:08 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-automating-injection-molding-processes-improves-efficiency-part-2/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [20] => WP_Post Object ( [ID] => 2264 [post_author] => 3 [post_date] => 2023-01-23 14:34:00 [post_date_gmt] => 2023-01-23 19:34:00 [post_content] =>Ferriot works hard to provide high-quality custom injection molded parts while remaining cost-effective and delivering on time. That's no small task, and one of the ways we do this is by utilizing many class-leading technologies in our custom injection molding operations. In previous articles, we've discussed everything from robotic arms and inspection scanners to mold flow analysis.
In my latest interview, I spent some time with Jeff Hodnick, our Automation Engineer, to learn more about his role at Ferriot. Jeff's been with us for the past three years, putting his nearly decade-long engineering experience to work on behalf of our customers by integrating new automation technologies to streamline processes and improve efficiencies.
Liz: Tell me about the different automation technologies that you get to use—like 3D printing and cobots. How is Ferriot using them?
Jeff: A large portion of what we do with 3D printing is fixturing. Primarily we make a lot of nests and related items, like how many companies fabricate them with resin. At Ferriot, we will design the nests in CAD using programs like SolidWorks and then do a 3D printout instead. So, we can use nylon and more robust stuff like carbon fiber-infused materials to get the same strength with less weight. We're tinkering more with end-of-arm (EOAT) stuff and 3D printing, but not too heavily; we've only made Gripper fingers and brackets so far. We saw some success with it, but the use case is primarily for nests and fixturing.
Liz: How does the end-of-arm tooling work as it relates to the 3D printer
Jeff: Right now, we use EOATs, the tools that go on the end of robot arms, to pick parts out of the injection molding presses. In some cases, some parts are hard to grab, and you must go at it from a specific angle, and there's no flat surface, but you still need to be able to grab the part out of the press. We can custom design whatever gripper type we could ever need, and 3D print it Then we're able to go in and grab parts that way. We buy grippers without any actual fingers on them, then design and print what we need for the specific application.
We would use them primarily for stuff like that. Or if it's a small, confined space, we must use a really small gripper, but the part is wide for that space, then we will use them in that regard too. It's kind of like boosters to go out wider to grab the part.
The significant advantage of being able to 3D print for EOA tooling is the customization and flexibility that it offers. It eliminates or at least reduces any restrictions we may have had before because of space issues. If we can mold the custom part in our machine, we can get it out with our custom designed EOA tools.
Liz: What are some of the limitations you run into with off-the-shelf EOA tooling?
Jeff: The limitations are size-related because they have standardized stuff that works for probably 75% to 85% of typical applications. But as soon as you get into the more custom molded part designs, that's when the 3D printing EOAT capability really shines. And Ferriot specializes in custom injection molded parts, so it's important to us.
Liz: Most of us are familiar with the grippers and suction cups at the end of a robotic arm. Can you give me an example of a custom EOAT that you might need to create?
Jeff: Yes, the suction cups and grippers are your standard go-to stuff. And they work for 90-95% of things. It's just that small 5-10% of the stuff that has no flat surface where the standard EOA stuff won't do the job. I would have to say that the majority of the 5-10% are angled parts—where the pieces come out (of the press) at an angle, and there's no flat surface, so you can't use suction cups, you can't use standard grippers, or the gripper might mar the part's visible surface—different situations like that. So, being able to bring custom EOA tooling designs to life, that's where 3D printing can be a huge help.
Liz: Besides giving Ferriot the flexibility to create the customized parts that our customers might need, do you use 3D printing for anything else?
Jeff: In addition to the custom EOAT tooling, we also use the 3D printers for our quality department, making tool holders and organizers, and stuff like that. Because it's quick, because they have a lot of specialized tools that are outside the norm shape wise
Liz: Rapid prototyping?
Jeff: Kind of, but only internally, more like rapid deployment as part of our process. The quality team has a lot of specialized tools and stuff that they use for specific customer projects. For us to be able to make a container for them to store it in, and do so quickly, that's ideal. You're looking at five times the cost if you were to have one of those things custom-made for it. That's a significant cost-saving measure for Ferriot, and it's customers.
In the next installment, I will talk with Jeff about how Ferriot combines our cobots and vision system technologies to further automate our custom injection molding processes.
How do Mold Flow Analysis and Tool Design impact injection molded part quality? [Part 1]
New Scanner Adds Color and Clarity to Injection Mold Inspection Data
Cobots Enable More Efficient Manufacturing in Injection Molding
Consider this scenario: Despite your best efforts, your custom injection molder continues to miss critical deadlines or is producing and assembling your project at an unacceptable error rate. Bottom line: It costs you much more than you had budgeted and has become a problem that needs to be fixed.
What are your options? Can you afford to switch to a new manufacturing partner?
Many companies choose a supplier to provide custom injection molding services, finished assembly, or decorative assembly from a third party. This approach can be a great production solution, especially if the actual operational delivery of your product isn't your company's forte. If you're working with a supplier in such a capacity, and the relationship has some history, you might be inclined to stay with your custom injection molder and just ride it out. However, if there are ongoing problems, finding a new source might be easier than you think.
If your work through the "break up" methodically, you can realize the cost savings and production improvements you desire without missing deliverables. There are several things to consider when making the decision to move injection molds from one supplier to another.
The ideal solution is one where the existing supplier, new supplier, and customer can openly communicate while maintaining all your deliverables. However, when this is impossible, having a supplier experienced with this type of transaction is invaluable. There is no substitute for experience and comprehensive planning.
The first step is establishing a sufficient inventory buffer before transferring the business. You want to avoid getting caught with too few parts on hand and causing an interruption in your business. At this stage, the current and new suppliers have specific responsibilities to ensure a smooth handoff.
Next, you'll want to clarify the deliverables regarding delivery, service, costs, and quality with your new supplier. It's a perfect opportunity to implement the improvements or enhancements you've been meaning to address—but didn't—because you didn't want to rock the boat. As the customer, you are also responsible for communicating known problems to your new supplier. If you want them to succeed, give them their best chance by communicating your goals and issues. Clear communication is critical at this point (indeed, throughout the entire process).
After everyone is on the same page, you'll want to ensure all parties are on board with cosmetic standards for the parts to avoid interpretation errors later. We recommend retaining each mold's last "acceptable" shot (part and runner attached if applicable) before transferring.
Finally, you and your new custom injection molder should develop an action plan to resolve any outstanding problems in accordance with future production needs and order of importance. Doing so will provide a successful foundation to build a lasting relationship.
To learn how to accomplish this process, download our guide, Mastering the Shift: 7 Key Points for Smooth Injection Molding Supplier Transitions. They say breaking up is hard to do, but with the right contract manufacturer as your partner, it doesn't need to be a heartbreaker.
Designing Injection Molded Parts
Injection Molded Checklist
Cut Costs on Injection Molded Parts
7 Aspects to Identify When Designing Injection Molded Plastic Parts
In Part 1, we discussed mold flow analysis (MFA) and the ways Ferriot uses it to improve the tool design process and, ultimately, the quality of the final custom injection molding we perform for our customers. In this segment, we’ll address questions about the Ferriot team's experience using MFA, the types of problems and pain points that have been discovered and resolved, and an example of savings that one customer experienced as a result.
Liz: Is this a pretty common process in injection molding with other companies? Or is it something that Ferriot feels is a strength that we bring to the customer?
Jerry: Although it’s a common process, there are a lot of companies doing injection molded part design that do not do mold flow analysis. Some people that build their own molds and are responsible for getting molds don't have this service. A lot of design shops don't have the experience to link part design with mold design and properly address how those two design processes marry together.
Not a lot of companies have this software and offer the link between evaluating things in the 3D world and the actual finished parts sitting on your desk. So, yes, this is one of Ferriot’s strengths, and it helps bring to life or show designers that aren't that familiar with plastics, the issues that they may have created unintentionally.
Liz: I can see where this provides both an experience edge as well as a consultive edge when you're working with our clients. I imagine that it’s especially helpful for designers that are not that familiar with injection molded parts. Is that correct?
Jerry: Right. For example, we get requests from startup companies or design houses that are industrial designers. They are looking for how a part is going to look or feel in their hands, but they haven’t taken into account how they're actually going to make it. By coupling our experience with MFA, that gives them a check and balance, per se, of their design. A saying I saw long time ago is so true: “For every vision, there's an equal and opposite revision.” We're trying to help prevent those revisions from happening after the mold is built.
Liz: I imagine that it gets costly.
Jerry: Yes. Once the mold is built, every change you make to it, you're looking at thousands of dollars. However, if we do an MFA with them before they started their mold, the little tweaks and changes are all but free. So, if you’re developing a new product and it includes injection molded parts, it pays to do your homework upfront. That's where our expertise in consulting and working through part designs with the customer prior to mold build, pays for itself and is a value-added benefit that we provide.
Ferriot engineers consulting with customer on possible mold design improvements
Liz: How long has Ferriot been offering the mold flow analysis and the tool design?
Jerry: In-house, we've been doing it about 18-months, going on two years. Up until then, when we were awarded a project, we would have our mold makers do it for us. Basically, every mold that we would build, would have this analysis done on it. Now, we’re doing this analysis in-house, and we’re doing it at the quoting phase, or to double-check everything at the quoting phase.
We've actually been providing the analysis for years, either by contracting the service or having a tool shop do it for us and working with them to get the analysis done. Later in 2019, we made a significant capital investment to bring in the tool internally so we can perform the analysis here at Ferriot on our own, saving time and money, while providing better control over it.
Liz: How many Ferriot people are trained to utilize the MFA software?
Jerry: We have three tool engineers that are trained to perform the mold flow, mold filling analysis. We also have process engineers who, although they're not trained to do it, they're very familiar with it and help to interpret results and review results and act as resources for the tool engineers as the analysis is being done.
Liz: What are the typical problems that you find when you do the MFA?
Jerry: It’s best to start with product design problems that we might unearth, and then move into tooling. One problem that I'm working on with a customer, we got the test part in, we quoted it, and we were awarded the job. We ran a filling analysis and with their material and due to the wall thickness, the part wouldn't fill. We tried multiple gating scenarios, to see if it would fill. It wouldn’t fill. I went back to the customer said, "Hey, this is the issue. We can't do anything about it without changing the wall thickness." Being proactive, we changed the wall thickness 20,000th of an inch and were able to fill the part. However, when we shared this solution with the customer, they said, "No, you can't change the wall thickness." The customer came back to us with three different resins. We ran the filling analysis and determined all three of them would work.
Example MFA simulation of nozzle boot flow fill time
But then they then came back to me later, "Well, we need to know if this is going to warp or not." We then ran a warpage analysis on all three resins, and now they're evaluating the warpage analysis to see which would be the best to use. So, thin wall thicknesses on parts or thin wall areas on parts could be bad, causing the material to somewhat hesitate as it flows through the part. Knowing that helps us advise the customer, "Hey, you have a part design problem here, you need to address it, and here are some ways to resolve it." The filling analysis gives us a lot of vital information of possible problem areas on parts, including issues related to wall thickness. If a rim or something is too thick, the analysis will show us a sink or a little dimple on the outside surface of the part. We can show that to the customer and say, "Because this wall is really thick, you're going to have a visual defect on the outside of that area." Sometimes it's okay, and they need the strength of that wall to be thicker, or "Oh, we didn't realize that was so thick, let’s thin that down and see if we can get rid of that visual defect."
Bottom line: There are numerous detailed reports within the results of the MFA, not only the answer to “will it fill properly?”, but it will identify areas that may not hold up under stress, where the hot spots or thick areas are in the mold. All of that data is available to review with our customers so they can alter their part design, if needed, to reduce or eliminate any problems.
Liz: Are there any interesting pain points that you guys were able to solve using this process? Are there any unique benefits that you've been able to offer customers because of having it, especially having it in-house?
Jerry: I immediately think of the value of being able to identify filling issues, even at the quote phase. If we are asked to quote a part, we can look at it and do it very fast analysis to identify filling issues that might stop the quote right there. We'd then let the customer know, "We can't quote this the way it's currently designed. We’ll have to talk about how to modify the design before we can provide a quote."
A lot of customers aren't even aware of these potential issues until we do our MFA. We've gotten quotes in from other people, and when we come back to them with this red flag, it kind of throws up a red flag of their own. Then they’ll ask, "Well, how did these other people quote it for us, and why didn't they bring up this issue?" So, it helps get into the nitty gritty of quotes and parts early with customers, which gives the customer a good, comfortable feeling about Ferriot, that Ferriot's providing them an extra service to help assure better parts. Hopefully, going that extra step helps us win their business.
Liz: How frequently do you find issues when you're dealing with mold transfers?
Jerry: I can speak for myself that I don't do a filling analysis on a mold transfer, unless we do have problems, but a lot of times there's not a whole lot we can do. That mold is built, it's been running production somewhere, and the customer is usually happy with the parts.
Now, if we have an issue with the part, you may be able to go back to the customer, run a filling analysis and say, "Hey, we're having this issue because of this issue." And I can show them the filling analysis of what's happening with the plastic as it's going around. Out of 50 transfer molds, that may happen once or twice.
Liz: So, the vast majority of mold flow analysis are done on parts in development, or molds in the tooling stage.
Jerry: Yes. It's a simple engineering tool that helps you make the best decision before that mold is built. The cost of the software quickly pays for itself. If you miss something that you have to make a mold design change after the mold is built, it pays itself a couple of times over just by preventing those future costs.
Liz: Can you give me an example, a success story of how MFA saved costs?
Jerry: A very large customer of ours came to us with a new product, which is highly visible. They were very concerned about strength. We ran multiple filling analysis for them to try and manipulate where some weld lines were going to be. Weld lines, whenever they are formed, they're weak areas of the part. We ran three or four analyses for them to get those weld lines moved: one, off a visual surface, and two, off of structural areas. If we wouldn't have done that, this mold cost us in excess of $200,000, we probably would have been redoing half of it. So, that was an exceptional savings in both time and money.
Liz: That’s a great example! For those of us who don’t know, please explain what a weld line is?
Jerry: To make a hole on a plastic part, there has to be steel in that area of the mold. Imagine the plastic is flowing like a river. The piece of steel that's in the mold to create the hole, think of that as a rock in the middle of the river. Now the water hits that rock, it has to flow around it, where the water comes together on the downstream side of the rock, or come together and welds itself back together, that’s what a weld line would be. It will fill in, but it's not as strong. That's a weld line. If you look at it closely, a tiny little line in the surface of the part. Eventually, as you get further away from the hole or further downstream, then the plastic starts flowing consistently again. But where it comes around that hole or the rock, it slams itself together.
By adjusting gate location, cooling, and other parameters, we can move the weld lines around in the part. When using the mold filling analysis, we can project where they are going to occur. The weld line is a slight visual imperfection, and it has a reduced strength. It's important to the customer where that weld line is going to fall in part. By using MFA, we can predict where it's going to occur and move it, if we don't have to, by making adjustments to the tool design.
Liz: How would you summarize the mold flow analysis (MFA) process advantage?
Jerry: Simply stated, it’s an engineering tool that helps Ferriot and its customers make an informed and educated decision before moving forward with the development and creation of the actual mold, saving both time and money, while resulting in a stronger, higher quality end product.
If you have a question about mold flow analysis and how Ferriot can use it to help you with your next injection molded part tool design, feel free to contact us for a FREE initial consultation.
[post_title] => How do Mold Flow Analysis and Tool Design impact injection molded part quality? [Part 2] [post_excerpt] => Ferriot offers in-house mold flow analysis (MFA) as part of our custom injection molding design process | See the real-world impact of design on molding [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => how-do-mold-flow-analysis-and-tool-design-impact-injection-molded-part-quality-part-2 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:09 [post_modified_gmt] => 2024-03-11 20:11:09 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-how-do-mold-flow-analysis-and-tool-design-impact-injection-molded-part-quality-part-2/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [23] => WP_Post Object ( [ID] => 2268 [post_author] => 3 [post_date] => 2022-03-24 13:55:00 [post_date_gmt] => 2022-03-24 18:55:00 [post_content] =>
To properly benefit from the advantages of using structural foam parts in your product’s design, first, you need to understand the process.
Here’s how it works. The structural foam injection molding process uses a foaming agent (typically nitrogen gas or chemical blowing agent) added to a resin polymer as it melts, then injected into the standard injection molding tool (or die). In this process, the blowing agent activates and pushes resin uniformly into the cavity pockets; as the part cools, a solid skin forms against the mold. Inside the mold, the resulting foaming action produces a honeycomb-like structure behind the solid skin while reducing post-mold shrinking.
The resulting structural foam part is significantly lighter than other parts produced using other standard injection molding processes. The majority of structural foam parts utilize this injection molding method to reduce the overall weight of the part by up to 30%. However, lower weight isn’t the only advantage. Structural foam molding can provide several benefits you may want to consider as you plan your next project.
The key to using structural foam parts successfully is in the ability to incorporate them into today’s complex custom mold designs. To learn more, download our whitepaper, Structural Foam Injection Molding Resources Guide.
To learn more, download the Structural Foam Injection Molding Resources Guide
Mold flow analysis (MFA) and tool design are both very important aspects in the injection molding part design and troubleshooting process. They help assure that a new mold tool design will yield quality parts that meet or exceed expectations.
Jerry Graf is the Manager of Engineering and he’s in his third year at Ferriot. He has about 36 years of industry experience, a lot of it in the automotive industry. Over 10 years of this experience is focused on the injection molding side of things.
In this discussion, I had the opportunity to learn a lot about MDA and tool design by talking with Jerry on his experience and expertise.
Liz: Could you explain a little bit about mold flow analysis and why Ferriot uses it?
Jerry: When I begin a new part design review, I use it mainly to determine the best place to gate the part. That, coupled with talking with the customer on visual requirements. I want to make sure I'm not gating on an appearance surface. That's kind of the first step is determining where I can gate it. Then, I would go in and model a 3D part file using a gate location and size that I think would fill the part based on the wall thickness of the part and on the material that they specify. Finally, I'd run a filling analysis to see if the part would fill.
If that is successful, then the next step would be to do a warpage analysis to see if there's any internal stresses created by that gate location that was chosen and see if the part will work. If it will work, will it be acceptable to the customer in the final assembly of the part? Another thing that the filling analysis will do is give me an idea of where some visual defects may occur, such as weld lines and flow lines, which usually occurs or always occurs around openings in the parts or holes in the part. Sometimes we want to keep those weld lines off appearance surfaces. For example, if a gate would need to be moved to push that weld line in the location where it would be inaccessible for the customer to see.
Liz: You referenced the term gate a couple of times. That is where the materials come into the mold, correct?
Jerry: Yes. The plastic goes into what we call a runner, from a machine into a hot runner, then to a cold runner. Then the cold runner enters the gate. Think of the gate as where you open up into the part. So, the gate is where plastic first enters the part.
Liz: So, what would happen if a gate was incorrectly located?
Jerry: Well, once I do the filling analysis, if I share that with the customer and have them tell me "Yes, that's okay," or if it's visually acceptable, and then we will review the warpage analysis, and if the part is able to be filled. If it wouldn't fill, or if it was creating a visual defect that was unacceptable to the customer, then we would just pick a different gate location based off of their feedback of the visual requirements. We can run multiple analysis’ with multiple gate locations, just to emulate all that happens in the tool before we build the mold.
Liz: Is there any other critical information that the mold flow analysis would provide?
Jerry: It also lets us estimate cycle time, that is, how long it will take to fill the part, cool the part, and get it down to a temperature where it can be ejected from the mold. Knowing the cycle time information helps us better estimate the piece price. It provides a more accurate representation of what our costs would be and what the piece price would be.
If we get a warpage condition that is bad, we may determine to hold it in the mold for a little bit longer, which the software can simulate. And then, we're going to see if we can get our warpage to an acceptable level, which helps us again, determine cycle time or how many parts we can produce in an hour, which influences piece price.
Ferriot engineer reviews MFA software simulation looking for opportunities to make improvements
Liz: All of that obviously influences not only the speed at which we can produce the parts, but also the quality of the parts, correct?
Jerry: Yes. If we go too fast, we could potentially have a quality issue. We use the MFA to make sure that the gates are in the proper locations, the material coming into the mold is going to do so smoothly, in the most timely, cost-effective manner and produce the best quality part for the customer.
To take it a step further, in every mold there are water lines flowing through it. The water helps the steel (of the mold) remain at a constant temperature. If we have some geometry that we're concerned about in the part’s design that's taking a really long time to cool, we can model-in water lines to cool that area of the mold better, to optimize the cooling of that part. We can model not only the plastic through the part, but we can also model the water lines going through the steel of the mold.
Liz: The objective is to make sure the whole part is cooling in a similar timeframe, and you don't have parts that are hotter and cooling over a longer period of time.
Jerry: Right. If you have an area in the part that takes longer to cool and another area that cools much faster and will be solidified, if you eject it too fast, there could be a lot of opportunity for warping once you eject it. You want the whole part to cool down all at the same rate. Now, we can manipulate the steel or even manipulate the mold steel by using copper, which draws the heat out faster. If we force water into that copper, it pulls the heat out even faster.
Running the filling analysis gives us insight into problem areas in the parts, areas that we should pay attention to in the tool design, and that give us a good representation of what would happen inside that tool before we actually start cutting steel, which is where it gets really expensive. If you start making changes after you’ve started building the mold tool, you could be scrapping pieces of steel as well as man-hours, which is expensive. So, it's not only beneficial from an engineering side, but it's also more cost-efficient to do the MFA before you start building the tool.
Liz: The value of MFA on the tool design process and the overall troubleshooting process is certainly becoming much clearer. Using MFA early in the design and development of the part makes sense. As long as the customer has a pretty good feel for the shape and size of the part, using MFA really helps move forward with the tool design in the most cost-effective manner.
Jerry: Yes. We'll step back a little bit further in the tool building process. Sometimes, I use MFA when I get a request to quote and we haven't been awarded the job yet. So, I'll use that to help give us a better idea of: Will the part fill? Is their design bad and we just can't fill it? Then, maybe at the RFQ, we'll go back to them at their time of quote and say, "Hey, we've quoted this way, but we see this issue or two that need to be addressed first."
Now, we typically only do that for customers with whom we've had a longstanding relationship. We don't always want to give our engineering work away for free, but if we have a good working relationship with a customer, then we're more receptive to do that at no cost to them. Now, if we are awarded the job, then yes, we immediately start into: Is the part moldable? Where are we going to gate it? Are we sure it's going to gate okay? Some of these items are very simple that we know it's going to fill just from experience in the wall thickness and the material or the plastic. However, there are times when there’s a red flag, "Hey, I better run an analysis on this just to make sure we can fill it."
To be clear, the mold flow analysis is not only helping guide the tool design, but it also can help guide the part and product design.
Liz: What if a customer doesn’t know what resin material to use in their part?
Jerry: Some customers do come to us with a part design, and they know the requirements of the part and they have narrowed it down to a classification of material. Based on that, and some of the physical requirements in its final assembly, we can make recommendations on some material to use, and run the filling analysis using different materials. This helps us guide the customer in selecting, not only the most cost-efficient resin, but one that would fulfill the physical requirements of the part after it's molded. Instead of building a mold and just trying a bunch of different plastics with it, if they're not 100% confident on the resin that they want to use, but have their specific requirements defined, we can take those requirements of the plastic and help them narrow down the selection.
Liz: So, it's entirely possible that a customer could come to you and say, "This is the resin I want to use for my part," and after you've completed the MFA, you guys might say, "Well, if you move from this resin to this resin, you'll end up with a part that's stronger and more durable for a little more cost."
Jerry: Yes. Or, if resin A is okay, but resin B is less expensive and still performs the same, we can also prove to them that, "Hey, we can get a little bit of cost reduction if your design will allow it." There are other considerations, things that could impact that, such as UL approval, other agency approvals, that kind of stuff. We must be careful with these recommendations, as some resins are approved and some are not.
Use of MFA can help avoid problems before completing a mold and taking the part to press
In part 2, we’ll answer the questions:
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The past few years have certainly had their challenges. The COVID-19 pandemic contributed to supply chain disruptions and limiting manufacturing capabilities to quickly get products molded, assembled, and to the market. That, coupled with the resin crisis resulting in higher prices and longer lead times, has made it more critical than ever to make smart injection molding resin selections.
At Ferriot, we've felt our client's angst. Everyone needs to adapt and adjust to meet their company's objectives. In some cases, that has meant evaluating the current resin selection and changing to another resin to keep production schedules on time and meet delivery dates without compromising quality and reliability.
The challenge is determining what resin is the right resin—the best resin—for the product. It’s essential to take some time to learn about the characteristics of thermoplastic resins. There are many different types and grades available, or in some cases, in short supply and hard to get delivered on time. These thermoplastic resins fall into two basic classes: engineering grade resins (nylon, polycarbonate, ABS, PC/ABS, TPE, acrylic, acetol, and structural foam) and commodity resins (polypropylene, polyethylene, polystyrene, and PVC). Each category includes various resins that provide the flexibility to match a resin to a part based upon application, part design, and moldability.
When considering all the product design requirements and the challenges of manufacturing a product in a post-pandemic world where the supply chain isn’t back to what it once was, resin selection can be a daunting task.
Over the years, we've provided several valuable guides to assist with resin selection, including The Tips, Tricks, and Traps of Injection Molding Resin Selection and the Injection Molding Resin Selection Workbook.
We've added the webinar, How to Make Smart Injection Molding Resin Selections, this year. This informative webinar addresses several important considerations when specifying resins for your next project. Learn the answers to these critical questions:
We think you’ll find the time you take viewing this webinar time well spent. If you have further questions, don’t hesitate to ask.
Learn more:
New press further increases customer service speed and production capacity
To help meet the increasing demand of custom injection molded parts in markets from electronics, to industrial and medical industries, Ferriot recently installed another press! Smaller than the Negri Bossi BI-POWER installed by Ferriot in 2018, the newest press in Ferriot’s line is the Negri Bossi s850T-7460 series molding machine.
As part of Ferriot’s equipment upgrades and plant reorganization, this new 936-ton press was installed in Q3 of 2020. The new acquisition adds capacity with the current 720-ton press still in operation. The new press fills a gap between the 770 ton and 1500-ton presses. Updates in technology allow this press to use less energy but provide more tonnage pressure and tighter tolerances.
“The new Negri Bossi press further increases our operational efficiency and production capacity. Adding this new press helps us to further instill confidence in our customers that we will always have the custom injection molding capabilities to quickly turn around their orders,” says Craig Ferriot, company president.
The Negri Bossi NOVA s850T-7460 incorporates the following features:
Negri Bossi Motus Multi-Touch Controller
Negri Bossi s850T-7460 series molding machine fills the gap between existing 770 ton and 1500-ton presses.
Ferriot’s current injection molding parts production fleet includes the following:
| # of Presses | 20 |
| Clamping Force (tons) | 56 - 2250 |
| Barrel Capacity (oz.) | 2.7 - 344 |
| Maximum Mold Weight (tons) | 20 |
| Minimum Mold Height (in.) | 5.9 |
| Maximum Mold Size (in.) | 60.9 x 89 |
Interested in hearing more about how we’re growing to service all your custom injection molding needs? Would you like to be notified when new blogs are posted? Subscribe to our blog so you never miss an update. If you have a question, don’t hesitate to ask!
Newly molded gas pump parts exiting the latest Ferriot press, a Negri Bossi NOVA s850T-7460.
Learn more:
Energy
The Russia/Ukraine conflict is rapidly evolving, and its global impact on oil and gas has yet to be determined. Consumers are currently seeing gas prices rise during this volatility. Inflated pricing will impact transportation and logistics, and the increased costs involved with moving materials will at least keep resin pricing up for the time being.
Logistics
High demand for goods continues to stress supply chain logistics for imported resins and resin feedstock. As of mid-February, we have ten orders to ship for every available truck on the road. Bulk trucking is having difficulty keeping up and experienced unexpected dropped loads recently in the Southeast US and Midwest due to winter storms.
Constraints on moving goods mean warehouse storage near our busiest ports is beyond maximum capacity, and they cannot accept additional containers until the containers that are waiting on the docks ship. Railcar storage is also beyond capacity due to the need for cars to be emptied and released. Collectively, this impacts port congestion, with all ports and sites near the ports being over 100% of the agreed-upon capacity.
Resin
Though resin producers have recovered from weather-generated shutdowns and planned plant turnarounds, demand remains strong, and prices continue to settle or increase slightly. Supply issues remain, so expect to see continued force majeures and sales allocation through 2022. Some inventories are beginning to grow, but additive shortages continue to impact availability. Overall, prices have bottomed out, but price increases will continue due to logistics and staffing issues and energy cost increases.
| Type | Pricing | Supply | Detail |
|---|---|---|---|
| Polyethylene (PE) |
Increasing Pricing is still up 26 cents per pound since January 2021, even after a 15 cent decrease from Q4, 2021. |
Sales have picked up with improved demand. Some limitations are expected due to planned and unplanned outages and co monomer supply issues. Transportation issues continue to plague export market. |
HDPE – supply available with forecast LLDPE Branded is available with forecast LDPE – tubular products fully available. Autoclave remains under supplier sales control. |
| Polypropylene (PP) | Steady to increasing. Pricing is still up 24.5 cents per pound since January 2021, even after 40 cent per pound drop between Sept – Jan. | Domestic supply is available. Imports have arrived, but are short-lived. December production below 70% was unexpected due to strong margins and lack of weather events. January is also light production month. | Rail car availability is a constraint to production levels. Spot pricing is moving up. Imports slowing. |
| Polystyrene (PS) | Steady to increasing. | Lack of import availability | |
| ABS | Volatile and increasing | Imported ABS keeping domestic pricing up. Ocean freight increasing exponentially, sometimes doubling in one month. Ports overloaded with peak season surcharges being assessed to Ocean Freight. |
Strong demand, continued raw material shortage and unprecedented logistics issues continue for imported ABS. |
| PVC | Slightly up but flattening. | Most suppliers have lifted Force Majeure, but maintain order limitations. | There are still sourcing constraints on additives and plasticizers limiting some availability, driving prices up and extending lead times. |
| TPE | Steady | Materials available | |
| Polycarbonate (PC) |
Firm Pricing will remain firm for first half of the year. |
Several Covestro suppliers are still on Force Majeure or sales allocation. Additives (especially FR): ABS and Polyester are very challenging. |
Makrolon and Bayblend remain on sales allocation with 11-13 week lead times. Makroblend (polycarbonate / Polyester) remains on Force Majeure with a 13 week lead time. Polycarbonate is not the issue. |
Difficulties in supply chain logistics continue to add to resin lead times. This is especially true now that the Christmas season is upon us with consumer goods competing with raw materials on cargo space. Imported material is impacted by container availability and congestion at the ports. Even once containers arrive and are offloaded, trucking availability and persistent congestion at rail terminals add to lead time. Resins produced in North America can also have delays due to limited availability of trucking and driver shortages.
| Type | Capacity | Comments |
|---|---|---|
| Bulk Trucking | VERY limited – demand is exceeding supply. | Supply/demand imbalances seen in the Southeast US and parts of mid-west (Kansas City & Ohio). |
| Dry Van: Full, partial & LTL | Limited – demand exceeds supply, reducing service levels and increasing cost. | Truckload market under-capacitized and carriers moving to LTL network. |
| Shipping ports | Port congestion continues to be EXTREMELY problematic delaying delivery of imported containers and increasing costs. | Downstream bottlenecks contributing to slow movement of containers. Some are being routed to other US ports. |
Though resin producers have recovered from weather generated shut downs and planned plant turn-arounds, demand continues to be strong and prices continue to be settling or slightly increasing. Supply issues remain, so expect to see continued force majeures and allocation into next year. Some inventories are beginning to grow, but additive shortages continue to impact availability.
| Type | Pricing | Supply | Detail |
|---|---|---|---|
| Polyethylene (PE) | Prices settling and remaining flat. | Supply continues to improve with only a few issues with some additives. Still strong domestic demand, but inventories now climbing due to reduced exports and plants running after shutdowns and turnarounds. | HDPE – improved LLDPE C4 available, C6 & C8 grades remain snug LDPE – some branded material remains under sales control. |
| Polypropylene (PP) | Prices settling. | Imports hitting US market at double 2020 average. Plant operating rates improved and inventory building partially due to September sales decline. | Potential limitations on key materials: Peroxide shortage impacts high melt products. Additives for resin stabilizers imported from China seeing delivery delays. |
| ABS | Volatile and increasing | Ocean freight increasing exponentially, sometimes doubling in one month. Ports overloaded with peak season surcharges being assessed to Ocean Freight. | Strong demand, continued raw material shortage and unprecedented logistics issues continue for this import. |
| PVC | Slightly up but flattening. | Most suppliers have lifted Force Majeure, but maintain order limitations. | There are still sourcing constraints on additives and plasticizers limiting some availability, driving prices up and extending lead times. |
| TPE | Steady | Materials available | |
| Polycarbonate (PC) | Pricing up | Several Covestro suppliers are still on Force Majeure or sales allocation. Additives (especially FR): ABS and Polyester are very challenging. |
Makrolon and Bayblend remain on sales allocation with 11-13 week lead times. Makroblend (polycarbonate / Polyester) remains on Force Majeure with a 13 week lead time. Polycarbonate is not the issue. |
| Acetal | Expect price increases to continue. | The market is short due to strong demand, import shipping issues and force majeures. Lead times extended on imports. Texas plants still on Force Majeure due to weather related issues. | Shipping costs are sharply rising and Methanol prices are higher. |
| Nylon | Further increases expected | All supply is very tight. Production is improving but backlog of demand will keep producers including BASF on Force Majeure. | Nylon 66 pressured for further increases due to raw material cost. Nylon 6 compounds are up as well. |
Last month, in our article “How to Get Your Injection Molded Parts On-Time and Keep Your Production Lines Running,” we addressed the lead times and production concerns around the resin industries and what Ferriot is doing to help our customers weather the storm. We will continue to update you on this evolving issue.
Plastics processors all over the country are seeing severe resin shortages and staggering price increases. Every indication is that this issue will continue through June. What caused this? What resins have been impacted? How will this impact the resin market in the coming months? What should OEMs with plastic components in their products be doing now?
What Happened?
The root cause of this crisis is the COVID-19 pandemic (see diagram). 2020 and the beginning of 2021 have been a battle, especially for Texas and Louisiana resin manufacturers. Like many, resin manufacturers experienced some shift in product due to COVID-19 disruptions. To abide by COVID-19 rules and regulations, many plants ran into staffing issues as production facilities, shipping ports and supply chain logistics all saw a slow down when quarantined production shifts removed days of labor, as well as short staffing because of symptomatic employees. As a result, many thermoplastic resins were already in tight supply. Then, in the middle of the COVID-19 pandemic, the south saw one of the worst hurricane seasons in years causing increased delay, as well as damage. In February, the United States was hit with Winter Storm Uri resulting in power outages across the country.
Timeline of issues impacting resin supply (Source: MAPP and AMCO Polymers)
Current Market Status
Now, several weeks later, the Louisiana and Texas plants are still recovering from the national winter/ice storm that caused so many shut-downs. Subsequently, there is more demand than supply for thermoplastics. According to Plastics Today, as of last week, at least 80% of domestic resin producers are in force majeure. Polyethylene, Acrylonitrile Butadiene Styrene (ABS), Polyvinyl Chloride (PVC), Acetal, Polycarbonate and Nylon being several major polymers that have been affected by this crisis.
Price increase announcements in Feb/Mar 2021 (Source: MAP and AMCO Polymers) Products in RED have supply on Force Majeure.
What does this mean for us?
Why does that matter to you and the production of your injection molded parts? Well, Polyethylene is the most widely used plastic in the world, 85% of U.S supply being created in Texas. Without Texas plants able to produce and ship these essential plastics, we are going to start seeing significant plastic shortages, and potentially empty shelves at the store, in healthcare, automotive, construction, etc. Remember how the toilet paper shortage of 2020 resulted from the COVID-19 shutdown? It resulted in increased high demand. Many plastics consumers are going to buy out supplies as we continue to see a decrease in product. What does this mean? Higher prices, ongoing allocations, longer lead times, etc. According to Plastics Today, Polyproplene resin prices alone rose an average of 34 cents per pound in February and are expected to continue going up through March as a result of the strong global demand and short supply.
But since the storm is over, we should be moving forward, right? Not exactly. As recent as last week, Texas was still working to restore power to those who still don’t have it. However, once power is fully restored, plants must then evaluate the effects that this storm had – product allocation, order status, lead times, transportation, etc. Most plants that were affected by freeze related shutdowns did not anticipate the shutdown having this high of an impact. As a result, most plants were unable to properly prepare production and machinery for what resulted in the shutdown.
What should we do?
As we continue through the resin crisis, Ferriot recommends working with your current supplier to confirm allocations, as well as future supply. The resin crisis will continue to get worse before it gets better. We are anticipating this crisis lasting through June, if not longer. Our engineering services team can work with you and your suppliers to help identify alternative resins that you can use while we navigate these strange times. Learn about the pros and cons of each different resin and see if an approach to pivot your resin selection in the short team is something that your business should consider. Then, be ready to give long-term commitments for supply today, knowing that this crisis is set to continue for months to come, and low-priced resins will likely experience a pricing increase as this resin shortage continues to be a battle we face.
How are we going to avoid this in the future?
As we work to get past this crisis, an important thing to remember moving forward is to have a committed branded distributor. Talking with your distributor about your forecast for the year and volume requirements will not only help them plan and prepare for your demand, but it will also keep your company top of mind if a crisis does occur. Right now, in the resin crisis, companies are submitting orders to manufacturers and are getting terms such as “30-week lead times” thrown at them. When you have a committed relationship and requirement already in place with a manufacturer, your forecasted supply is already being factored in, resulting in quicker product response times. Having a committed relationship will also allow you to have some “buffer stock,” on hand when these types of delays occur again. Lastly, remember, resin crisis or not, the more lead time that you can provide your supplier, the less you will have to worry about hiccups delaying your products again!
Conclusion
As resin plants continue to regain power and recover from the latest setback, companies continue experiencing productivity issues due to labor challenges of COVID-19 and supply of both domestic and imported resins continues to fall short and worsen, the resin crisis remains an issue across the country. Consult Ferriot’s engineering services team and your branded distributor immediately to develop a plan on how your company can combat this setback. As a reminder, the best way to address the current resin crisis is to be proactive by taking these steps now:
Resin Pricing Update: May 12, 2021
The resin market continues to face ongoing delays and shortages as a result of the Covid-19 pandemic, a record hurricane season, and winter storm, Uri. Many resin lead times are extremely long. The team at Ferriot continues to monitor the price fluctuation of our country’s most popular polymers.
- PGP settled down $.13/Lb. for April to $.57/Lb. Throughout the month of May, we are predicting that the pricing is going to decrease.
- Given the supply/demand imbalance, the market tightness remains for Branded Polypropylene. As of April 30th, seven out of 10 N.A. PP producers remain on Force Majeure.
- Pricing for Polystyrene continues to increase, and we predict continued price increased throughout May.
- ABS pricing continues to rise as well with a $0.61/Lb. price increase on general-purpose ABS since September 2020 and $0.32/Lb. on enhanced specialties.
- With three of the four major North American PVC resin production facilities still operating under Force Majeure, multiple PVC resin producers announced a $0.07/Lb. increase for March, with two producers announcing an additional $0.07/Lb. for April, with likely another on the way in May.
- PC is another that has seen shortages due to the series of many events that have put many manufacturers into Force Majeure.
- As for Nylon, all supply continues to be tight as production works to build back up.
Popular brands of blended resins still have long lead times as well:
-SABIC PC/ABS blends, Cycoloy and Cycolac still have a 19 week lead time.
-Covestro’s Makrolon (PC) and Bayblend (PC/ABS) still have a 13 week lead time.
In addition to the increase in individual resins, companies and locations across the world are still seeing the impact.
- Since September of 2020, a total of $0.62/Lb. of price increases have been announced by ChiMei. Lead times at ChiMei continue to stretch 12-14 weeks as the manufacturer sells out of all resins
- The cost of Taiwan to Chicago increased to $1,500
- While we continue navigating these shortages, excessive port delays and intermodal freight could add 3-5 weeks for delivery for any resin
Demand is expected to continue to be strong through the summer months with raw material costs increasing. As companies work to bounce back, they are also tasked with the ongoing battle of long lead times that keep them under Force Majeure. Throughout these months, it is important that we are planning ahead when we can, as well as substituting preferred resins for alternatives when available.
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When reviewing projects with your injection molder, remember to discuss what value-added or secondary services they provide beyond molding your parts. Consider selecting one company that can handle all of your custom injection molding, painting and decorating needs. Using an injection molder with comprehensive services that include painting and decoration capabilities saves time and lowers your cost.
Two-color pad printing machine
When you work with an injection molding company that also does the painting and the decorating, your production lead time is minimized because no additional transit time is added to ship parts from the injection molder to the company providing the finishing services. This also means that there is no additional freight cost added to the final cost of the finished product.
Working with a company that does both processes in-house also means more time can be saved because full-service injection molders can optimize the production, painting, and decorating of your products efficiently and in a cost-effective manner. Manufacturing cells are flexible and customized for the products being made. A good example of this would be an enclosure with specific color requirements and a company logo. An injection molder with painting capability can look at the options of color matching the resin versus painting the parts once molded. This optimizes your products, and gives you options where cost, appearance and performance can be considered before making the final decision. Once you determine the process for achieving part color, the method to be used for application of the logo can be considered.
The most common choice for incorporating brand names, logos, instructions, and other markings on plastic products is pad printing. Many customers are drawn to pad printing because it provides the capability to place a 2D image onto a 3D surface. The process of pad printing utilizes a silicone pad, and its flexibility allows it to easily adapt to irregular surfaces that could have various textures or recessed areas.
In this example, pad printing is used for both two-color branding
and to provide warning instructions in black (top of part).
What are the advantages of pad printing?
When it comes to adding your brand or other information to your injection molded parts, pad printing offers some very valuable advantages:
Pad printing is particularly useful when the surface on which the logo and product name is must appear on an irregular surface. In this case, the imprint area is curved rather than flat.
Is pad printing right for my product?
The pad printing process is commonly used on products in many industries and numerous applications including:
There are 2-color and 4-color options that provide durable results whether you’re printing company logos, product names, user instructions, and operational indicators.
What details are needed for your pad printing job?
To ensure the successful pad printing of your injection molded parts, you will need to provide specifications, graphics, and set up instructions. The list below is a great guide to help you prepare for your pad printing job:
Visual instruction icons being pad printed
where controls will appear on the final product.
Are there additional pad printing costs?
Other than the ink needed, there are some one-time setup costs that could run between $1,000 and $1,500. Additional costs that you can expect when getting started with your pad printing project include:
| Holding Fixture to hold the part in place when printing | $550 |
| Artwork | $190 |
| Cliché image plate | $280 |
| Ink Color Match | $140 |
| Silicone Pad Print Pad | $75 |
One of the most common reasons our customers turn to pad printing is its cost-effectiveness. If you have high volume parts, need a limited number of colors and/or very small areas to print while maintaining high quality and tolerances, pad printing is a great choice.
Before any pad printing job, make sure that you review the project with your injection molder to discuss your unique requirements. They will know the questions to ask, and will understand how your application, shape, size, material and surface finish will impact your desired results allowing them to provide you with a quality product.
If you need further assistance, don’t hesitate to ask us your questions. We’re here to help!
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You’ve probably heard that a picture’s worth a thousand words. However, according to George Popov, quality supervisor at Ferriot, a picture’s actually worth a million numbers — at least in the world of custom injection molding part inspection.
Armed with just one piece of inspection equipment (a CMM), Popov was seeing his department become a bottleneck in the inspection process. So Popov and his team selected a new piece of equipment — an Aicon SmartScan scanner with third-party PolyWorks software.
Among the factors that influenced their decision was the scanner’s ability to present inspection data in a colorful, easy-to-grasp format. The PolyWorks software allows users to introduce a color map to the scanned image, showing where and by how much the part being inspected deviates from the CAD model of an ideal part.
The visualization of inspection data is key to connecting with customers. If a customer is struggling with a faulty part, the color maps and virtual inspection tools help illustrate the exact problem at hand. And it can confirm the accuracy of the inspection process and protocols being utilized.
But that doesn’t mean you should get rid of your CMM. In fact, Popov explained that the scanner and CMM work together to provide a more comprehensive inspection process. In addition to visualization, the inspection tools have helped Popov’s metrology lab increase throughput and enhance flexibility.
To learn more details from Popov’s interview with Plastics Machinery Magazine read the full article here.
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Cobots Enable More Efficient Manufacturing in Injection Molding
What is Gas Assist Injection Molding?
The reason for injection molding delays is that resins – the materials that your plastic parts are made from – are in short supply. With lead times for resins increasing and their cost going up, it’s only natural that your injection molded parts will face the same challenges.
Increased lead times and prices are significant obstacles for any industry. The problem is that these challenges may not be going anywhere anytime soon. The COVID-19 pandemic has caused a delay in resin production while simultaneously causing demand to skyrocket. Not only are plants slowing down during the pandemic, but many US companies are also reshoring production. Couple that with winter maintenance shutdowns and outages – both planned and unplanned – and you have the perfect storm for a volatile market.
Now, everyone is scrambling to get their resins quickly, and many companies are being left behind in the process. That means that, in the fast-paced world of modern industry, manufacturers relying on quality resins are going to face:
That’s why the resin experts at Ferriot are here to help you plan for success by meeting these challenges head-on so that you can keep your production lines running.
How is Lead Time Being Affected?
When everything is running smoothly, resin lead times are often rather reasonable. After sending in a purchase order, you could expect a resin in only a few weeks, a month at most. Quick resin lead times mean that you get your parts faster, and your business can continue running smoothly.
Current lead times may not look so bad at first. Quoting a lead time of about 4-5 weeks is pretty standard in the current financial climate… but those lead times are misleading. As the COVID-19 pandemic causes waves in the chain of supply and demand, that 4-week lead time can turn into 8 weeks a day later, and then 12 weeks the next. Before long, those initial 4 weeks will have passed with no end in sight.
Without the resin, you can’t make the injection molded parts that you need. The impact of the current pandemic has done a real number on manufacturers, causing many of them to put a halt on projects and hold off on any decision making until things settle down.
What Resins are Being Hit the Hardest?
When it comes to resin selection, there are two main categories of resins: commodity resins and engineered resins. Depending on which type of resin you need, you’ll face a slightly different market with its own issues.
If you’re working with commodity resins, you are most likely working with one of the following three choices:
These commodity resins have been facing increasing challenges with lead times and prices since the start of the COVID-19 pandemic. Since these more general resins are so closely tied with many different applications and products, they are the resins that are affected the most by the supply/demand cycle. Currently, polyethylene and polypropylene resins are even harder to get than polystyrene resins.
Engineered resins, also referred to as custom resins, are resins that are tailored to a specific application or product. Since these resins often lack the mass production of typical commodity resins, it has only been in the last couple of months that we’ve really seen a significant spike in lead times and prices.
What makes the selection process especially difficult for engineered resins is that you usually pay when the resin ships, not at the time of the purchase order like you typically do with commodity resins. This means that the price can go up as lead times are drawn out. Now, not only are you waiting a few months instead of a few weeks for your resin, but you’re also paying more for it than you expected.
No matter how or why a resin costs more or takes longer to get, all of these things will directly affect the lead times and prices of their resulting plastic parts.
How Do I Get My Production Up-And-Running Faster?
If you want to overcome the current challenges of the resin market, then you’ll want to partner with a resin selection expert like Ferriot.
In order to keep our customers competitive, we’re implementing a number of key initiatives to help mitigate the effects of the current pandemic on your production lines. The goal is to mitigate downtime and allow you to push forward even in these challenging times.
Controlling the Controllable
We can’t control what other companies do or how the market shifts. However, there is some work that we can do upfront to help you get your resins as quickly and as cost-effectively as can be.
By partnering with the injection molding experts at Ferriot early on, we can help streamline your time to market. We can also help to manage resin lead times through our supply agreements and by ordering as soon as you select a resin.
Planning for Unpredictability
If you want to plan for success in a changing market, you need to remain agile. That means having a backup plan.
As you are planning out your design, the resin experts at Ferriot can work with you to come up with a backup resin (or two!) that can still fulfill your design needs. Specifying more than one resin on your prints is the most important thing that you can do if you want to ensure that you get your injection molded parts as fast as possible.
By selecting multiple resins, if your first resin choice is too costly or has an exorbitantly long lead time, you can still get a usable resin within your desired time frame. That flexibility also helps to manage any risk of a resin being discontinued or being single sourced.
Specifying multiple potential resins gives you the flexibility to continue production on existing products, as well launch any new designs. Ferriot can also help you to negotiate better resin prices while safeguarding against rising costs by locking down prices earlier.
To learn more about getting the right resin for the job, take a look at Ferriot’s Injection Molding Resin Selection Workbook for more information.
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When it comes to new technology, what makes it a success? The platform? The interface? The added features? No, in fact, it’s all about the talented people involved with implementation.
At Ferriot, we know what it takes to decrease failure rates and guarantee success with the new technologies that we implement to better serve our customer’s custom injection molding needs. And we know how the success of any new technology relates to the people implementing and using it to do their jobs better. The way the people in your organization work together to handle both simple and complex problems contributes to your organization’s culture.
To make new technology a success, your culture should manifest the following skills and strategies:
Before you start planning a new technology implementation, take inventory of your team’s interactions — especially when facing challenges. Is there a strong sense of trust? Is there a shared feeling of comradery? If so, your team is much more likely to experience a successful outcome.
We recently talked about this subject with Industry Week. To learn more, read the full article here.
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The year 2020 has been a tough one, especially for manufacturing. Due largely to the COVID-19 pandemic, the manufacturing industry saw a decline of nearly 23 percent in 2020. The simultaneous shock and demand from shutdowns, the financial crisis, and increased workplace regulations have created the perfect storm for what’s likely to be the worst hit to manufacturing we’ve seen in decades.
However, in light of recent times, businesses are still finding ways to rise above and prevail. Through advanced processes and increased technology adoption, manufacturing companies can, and will, survive the storm.
Now more than ever, it’s important to recognize good manufacturing and the smart businesses that are leading the charge for long-term, sustainable growth. That’s why Ferriot is honored to be among the 35 companies receiving a 2020 Business Growth Award from Cascade Capital Corporation.
Recognizing Success
To help reinforce the positive during these times of uncertainty, Cascade Capital Corporation has recognized 35 Northeastern Ohio companies at their 2020 Business Growth Awards Program. These awards showcase a company’s continued success and growth, highlighting their crucial role in supporting and revitalizing the local/regional economy.
Companies can earn a Business Growth Award by either increasing sales by 100 percent/$5 million or by increasing its employee base by 50 percent/25 people during the past five years of business. The profits, goods, and services generated by these companies help to invest in the economy while opening new facilities and hiring additional employees.
On October 1st, Cascade Capital Corporation presented Ferriot and the other honorees with their award during a live virtual event. Companies that received an award will also be featured in a special editorial report in the October edition of Smart Business Cleveland.
Ferriot’s Continued Success
Here at Ferriot, we pride ourselves on being able to support our local economy and for helping to promote positive change for the manufacturing industry. Ever since our start in 1929, we’ve been able to provide custom mold manufacturing, injection molding, and a host of other manufacturing solutions for a variety of markets by focusing on adaptability and innovation.
At the onset of the COVID-19 pandemic, Ferriot was deemed an essential business. With many of our customers in medical, financial, and industrial markets, we were given the chance to continue operations during the shutdown.
Through new safety measures and organizational processes, Ferriot has maintained employment levels, while remaining focused on keeping our employees safe and healthy while continuing to support our customers’ supply chain. Most importantly, we at Ferriot have continued our mission of aligning the right people with quality processes, resulting in the flexibility and adaptability to meet the changing needs of our customers and fluctuating market conditions.
In these last five years, Ferriot has made a significant effort to reinvest in the people, technology, and equipment that have fueled our success. Last year, in 2019, we achieved our biggest sales year to date.
Together, we came up with a single word to help us all focus on our goal: Excel. To truly make a difference, we must empower each of our employees to use their own skills, creativity, and ingenuity to help improve the day-to-day operations of our business.
We cannot just do good enough – we must Excel.
People First
The first step on the path to excellence is our focus on people. Both our technical specialist and management teams must be given the proper training and ongoing support to do their best work. Teams must also operate harmoniously, empowered by the goal of continued excellence.
To support our teams, Ferriot has added key talent in technical areas to help reinforce our engineering support with quality process improvements to allow us to better serve our customers. All levels of management have also received leadership training, specifically that in working with cross-functional, technical teams.
Advanced Tooling and Technology
The right team needs the right tools. That’s why Ferriot makes certain to provide our employees with the best and most up-to-date equipment to help them identify and solve problems.
In 2015, Ferriot invested in new ERP Software, IQMS. This advanced software gave our teams real-time data and visibility into better managing day-to-day operations while maintaining business continuity.
We also make sure that our machinery is up to the tasks at hand by regularly reinvesting back into our operations, replacing aging injection molding machines and equipment with newer models. In 2018, we added our largest injection molding machine yet: a 2250-ton press. With press sizes ranging from 66 to 2250 tons, Ferriot has the flexibility to run a large range of products in-house, helping us to maintain quality and performance throughout our offerings.
Excellence for the Future
One big way that Ferriot is planning for the future is by investing in automation and new manufacturing practices. By testing out advanced mold flow analysis software, digital scanning technologies, and collaborative robots that can work alongside human operators on the manufacturing floor, we’re making every effort to set ourselves up for future successes.
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If there's one thing that every manufacturer knows, it's the value of a good operator. Operators are champions of production, driving the performance, efficiency, and reliability of your plant processes.
Unfortunately, great operators are often wasted on repetitious manufacturing processes, where most of their time is spent on mundane tasks instead of work that requires more "brainpower" and finesse. On those monotonous tasks, if operators are being forced to act like a machine doing the same thing over and over again, why not get an actual machine to do it?
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What's more, is that all these things can happen while also improving the jobs and lives of the operators. Contrary to popular belief, cobots weren't made to replace operators but rather enhance the workflow and save them for more important tasks.
Here's why Ferriot and other manufacturers are turning to the power of cobots to enhance plant productivity.
Cobot and Ultrasonic Welding Service
The High Cost of Manual Labor
A lot of manufacturing is doing the same thing over and over again. Unfortunately, humans weren’t made to do the same thing time after time with perfect reliability.
This lack of repeatability with human labor leads to significant inefficiencies over time, forcing manufacturers to accept a certain amount of lost time and bad products. It is human nature to find shortcuts, and people get bored doing the same thing over and over. There's no value-added benefit of having people in control of these tasks. It leads to reduced quality and the need for more labor.
When an operator has to do every mundane task on the plant floor, it also forces unneeded wear and tear on their bodies. This leads to operator burnout, which is not only a hazard to their personal lives but can cause them to underperform at work.
Overworked operators also don’t have the time to critically analyze the parts they're creating, which is bad for quality assurance. Operators are just moving parts and not really looking at them.
Cobot and Insert Welding Service
The Power of Cobots
With the power of today's technology, manufacturers no longer have to rely on human operators to handle every production task. Cobots can now handle all the repetitive and tedious elements of manufacturing, leaving operators open for more complex tasks and part analysis.
Not only does this save time on assembly, but it also leads to higher quality and more consistent parts. Manufacturers looking to add cobots to their production lines can expect measurably better parts, sometimes in half the time.
None of this should be worrisome for the operator, as many often misconceive that a focus on manufacturing robots and automation will take away jobs from the people that previously did those tasks. Cobots are collaborative robots. They don't take away jobs so much as they take away the bad parts of jobs, allowing operators to be happier, healthier, and more productive as they oversee the cobots and focus on more skilled work.
Ron Pack, Manufacturing Engineer at Ferriot, talked about the importance of cobots in a recent interview. "A person has to be involved somehow in almost everything with cobots, so you’re not taking away any jobs or disrupting operators," said Ron. "But the more you can automate the mundane parts of manufacturing, the more your operators can look at the finished product and make sure it's actually good. Operators are happier, and your parts are better. It's a win-win."
Better Manufacturing at Ferriot
Seeing the value that cobots offer to both manufacturers and operators, Ferriot has invested in new cobot technology to aid Ferriot’s team on the plant floor. Since the beginning of 2020, Ferriot has employed two cobots to assist our operators and improve our facility's performance.
Currently, Ferriot's cobots are working on six different parts, with plans to add four new parts to their workflows in the near future. "The increased efficiency and repeatability of the cobots has really been key," said Ron. "In some of our more important areas, we’ve seen efficiency gains of 60 percent or more."
Cobots have been a particular help in recent times due to the COVID-19 pandemic. They've allowed Ferriot to reposition its operators to better handle the changing environment in a time where recruiting new operators was difficult.
One thing is for certain – cobots will play an increasingly bigger role in the manufacturing plants of the future, creating better working environments for operators and manufacturers alike.
Is Your Culture a 'Good Fit' for New Technology? [Industry Week, Craig Ferriot interview]
Learn more:
It is important for designers to consider product requirements when parts are being designed for ultrasonic assembly. Joint design and resin selection decisions are impacted by these inputs.Ultrasonic welding requires specific areas of the parts to soften but not melt with increased temperature. This is why thermoplastic polymers and not thermosets are used for this application. Two main types of thermoplastic polymers exist – amorphous and crystalline. Amorphous polymers work best when using the ultrasonic welding process. Here’s the difference:Amorphous polymers do not have an organized molecular structure or a defined melting point. When heated, they gradually soften as they pass from a rigid state, through a glass transition, into a rubbery state, followed by a liquid flow in a true molten state. Solidification is likewise gradual. Crystalline polymers have a more organized molecular structure which causes the material to absorb vibration energy before it can be passed through to the joint area. This means more power is needed to weld them, and they have a sharper melting temperature. This causes difficulty in making a quality weld without damaging the parts. ABS, Acrylic, Polycarbonate, and PVC are amorphous polymers - with little or no crystalline structure, they are ideal for ultrasonic welding. Polyethylene, Polypropylene, Polyester, and Nylon are semi-crystalline and are still used in the ultrasonic welding process but are more difficult to weld.
For optimum assembly results, the three basic requirements when designing a joint are a uniform contact area, a small initial contact area, and a means of part alignment.
Ultrasonic welding of plastics is a reliable, consistent, repeatable process that provides a clean, strong, integral bond. The benefits make it widely accepted in many industries, including automotive, medical, electrical, electronics, communications, appliances, and consumer products.Injection molders who offer this value-added service work closely with design engineers and ultrasonic welding experts to find the most cost-effective solution yielding quality parts. Understanding design requirements for parts to be assembled can allow for a well-designed tool that produces superior results. Avoid NPI delays and tooling rework by involving your injection molder upfront.
Do you have a new product with multiple components needing assembly? Contact Ferriot to help you ensure a successful product launch.
In Part 1 of our discussion of the importance of TQM to the injection molding process, we introduced George Popov, our Quality Supervisor, and provided you with a behind-the-scenes look at what George and the Ferriot Quality Team are doing to implement and improve TQM on a daily basis.
In Part 2, George and I discuss a new technology acquisition, the AICON smartScan Structured Blue Light Scanner, and how it is helping Ferriot meet and exceed quality goals.
Liz: Tell me about this new scanner. How long have you had the scanner in-house and how are you using it?
George: We've been utilizing the new scanner for about 18 months. The AICON smartScan is a new state-of-the-art piece of metrology equipment that helps us to accelerate the injection molded part development process. It’s a blue-light scanner, that works in conjunction with PolyWorks inspection software. It enables us to scan physical parts into 3D images that can then be overlaid to the CAD model for that part and inspected very thoroughly.
One of the greatest benefits this provides is the color map comparison feature, which provides instantaneous visual results and allows us to see what is going on with the part before ever taking a single measurement. The color map provides a real indication of the distance between the actual part versus the CAD nominal surface. This is of great benefit to our customers, because it helps quickly solve any issues they are experiencing in the very early stages of part development and verification during the approval process.
Liz: How has that scanner helped the engineering and quality teams do their jobs better?
George: The scanner has the most direct impact on our quality department as a whole, but it’s especially valuable to the project engineers because they’re able to look at real-time data, visibly seeing critical details of a part that has been scanned. Right away, they’re able to tell where the problem points are going to be when we mold these parts in-house.
Most of the time we will actually get samples along with a transferred mold tooling. In fact, a lot of the molds we have are transferred tools, so we frequently get parts from different countries all over the world. We scan them and can see where they're at quality-wise before we actually mold parts with them—so we have something to compare to. If necessary, we can make quality improvements to the mold that’s been transferred to us, so t's been very helpful in that aspect.
Ferriot’s AiCON smartScan scanning an injection molded part using blue light scanning technology. Blue light 3D scanners offer better precision, accuracy, and higher quality outputs than white light scanners, laser scanners, and CMM.
Liz: I can imagine that saves a lot of time and aggravation! You told me that this scanner replaces about 80% of what used to be done with the Coordinate Measuring Machine (CMM). What is still being done with the CMM?
George: The things that are being done with the CMM are only the parts that we are not able to scan. What I mean by that is, with the scanner, what you see is what you get. If the cameras can see the features that you're trying to attain, then it will be able to measure them, or it will be able to capture an image.
However, if the cameras cannot see a feature such as deep channels or bosses, it does not do well with that because it can only scan so deep. Then we would put those parts on the CMM. In fact, the scanner and CMM can work together. You can do part of a program on the scanner, and whatever you can't get on the scanner, you can do on the CMM, which also saves us quite a bit of time.
So yes, we're doing much more on the scanner. That is our main device for gathering data now. Our CMM is pretty much our secondary or backup machine. We still utilize CMM. Actually, there are parts that we do on the CMM for programming purposes because it’s easier. Between the scanner and CMM, we have the flexibility to pick which is best for the project.
George Popov, Quality Supervisor and Walt Kravetz, Quality Technician, reviewing smartScan data in PolyWorks Inspector software.
Liz: Any interesting quality success stories since you've been at Ferriot?
George: One of the first customers we started doing scanning work for saw the data, and they came in and wanted to talk to us about what they thought was inconsistent data. They thought, they better make sure this scanner works because it's a new system and the data looks questionable.
What we were able to prove is how warped their parts were, and how it wasn't the scanner, it was actually the parts themselves that were so different. When comparing from part to part, they varied so much. I was able to show them that with the PolyWorks software that works in conjunction with our scanner. We could easily zone in on specific areas with which they were having concerns, and show them why they were having problems with them.
We were able to overlay the scan model over the CAD model and apply a color map. By manipulating the scale range for that color map, you can have a tighter tolerance to see where parts are out of spec, and how closely the scan model correlates to the CAD model.
By comparing the new scanner data and addressing their concerns, we were able to prove to them that the PolyWorks software is more than capable of giving them the precise, accurate data they needed. They were very satisfied with what we showed them, and their confidence level in our capabilities were established. They walked away satisfied with what we were able to do, and they felt comfortable that the data we gave them is good data. The fact that they can see the areas of concern without us even taking measurements was a huge deal for them.
Liz: Tell us a little more about the PolyWorks software and the value that it brings to the process as well.
George: Once scanning is completed; a mesh is created and then an STL file is used to inspect against a 3D CAD model in PolyWorks software…
Liz: …And what is the STL file and mesh that’s created?
George: Well, STL is short “Standard Triangle Language” and “Standard Tessellation Language.” STL (or STereoLithography) is an openly documented file format for describing the surface of an object as a triangular mesh, that is, as a representation of a 3-dimensional surface in triangular facets. We use the STL file with PolyWorks Inspector.
Liz: Ok. So, then the STL file is used with PolyWorks in what ways?
George: PolyWorks Inspector is a universal 3D dimensional analysis and quality control software solution. By using it with portable metrology devices like our SmartScan, we control tool and/or part dimensions, diagnose and prevent manufacturing and assembly issues, guide assembly building through real-time measurements, and oversee the quality of assembled products. The scanning software allows for smoothing and filling in of areas not scanned, based on triangulation and geometry of surrounding areas attained by scanning.
PolyWorks Reviewer is an easy-to-use software application that can be utilized by Ferriot’s cross-functional teams or even our customers in order to visually assess the injection molded part and any areas of concern. Put simply, Reviewer enables manufacturing specialists to dig deeper into the measurement database to analyze any dimensional issues highlighted by a metrology specialist. In Reviewer, controls can be searched, sorted, or filtered in the user-friendly Control Review Interface.
View of AICON smartScan data in PolyWorks Inspector universal 3D dimensional analysis and quality control software.
Liz: Previously, we talked about SPC and graphs. What is SPC and how is it used?
George: Statistical process control.
Liz: And you were saying that we could graph now, and apparently, we couldn't before. Is that correct?
George: Correct. It's a huge plus, and I think more and more companies are going towards SPC because it really gives us the tools to be able to control processes out on the production floor. That's what we're really geared towards—controlling processes. You can see on the graph when things get out of control, then you can make the call, “Hey, something's going on here, we need to get this thing back into control.” And then you can follow the graph and see your trends. Trend charting is huge and adds a great deal of value.
That's actually another thing I'm working on with the inspectors: I'm having them look at their trend charts to see how things are measuring on a day-to-day basis, and at production run after production run. As a result, we have that data now. The big deal about having this electronic database is being able to chart everything, being able to look at what they're inspecting. The whole visual aspect is very key. That's a big deal for us, and for our customers.
Liz: One last question. As quality supervisor, how would you describe the Ferriot advantage to a potential new client?
George: Well, that's a good question. I would say the Ferriot Advantage is that we are moving TQM in a direction of total customer satisfaction—from their supply chain and procurement people to the design engineers and quality control manager. Part of that is acquiring state of the art equipment that gives our customers, not just a warm and fuzzy feeling, but absolute confidence that the data that we provide them is accurate and precise.
Why? Because they're be able to see everything. It's a very visual system. And I don't know about you, but when I'm looking at a big spreadsheet of numbers, it’s easy to get lost quickly. But when I'm looking at a visual map, something easy to interpret with the eyes, then I don't need to guess where things were measured. At what point was this measured? How many points were taken to create this feature? Everything is visual. It’s right there in front of me. And it gives a very quick indication of the overall quality of the customer parts.
In turn, that allows us to make quick decisions on how to proceed. If the part is good, we can see that right away. And if not—if there needs to be tool modification—we can make adjustments. We can do it quickly. No surprises. We don't have to sit down over spreadsheet after spreadsheet and try to make an educated guess on which way to go, because that's very costly. In the end, it comes down to saving time, cost, and quality, all of which are reflected on the bottom line.
We not only want to get things out in a timely manner, but in an efficient manner. We don't want to just read through things and give data that we're not sure of. When we can put a color map and data side by side and it just jives like that, it gives everyone a good feeling and confidence that the support we're going to give is going to be second to none.
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Total Quality Management is critical to everything we do for our customers. At the end of the day, the goal is production readiness. Injection molded parts must be optimized for functionality, production consistency and ease of manufacturing. TQM includes everything from start to finish, from mold qualification to production quality.
However, for many of us at Ferriot, TQM is also our way of life. This is especially true for George Popov, the Quality Supervisor at Ferriot. George was able to take some time out of his busy schedule to discuss how Ferriot is dedicated to the process of continuous improvement when it comes to delivering quality to our customers.
Liz: How long have you been working in the quality field and with Ferriot as the quality supervisor?
George: I’ve been working over 10 years in quality. It’s getting close to three years with Ferriot, with about 10 months in a supervisory role.
Liz: What do you do at Ferriot as a quality supervisor?
George: I oversee the inspection team for both the molding and finishing departments. And I provide them with support on any issues they're facing, direction on how to perform their responsibilities. Of course, there’s much more, but that's basically what I do.
Liz: How large is your team?
George: It's a four-person inspection team, with a backup inspector for each shift in the Molding department and two backup inspectors for the Finishing department. Having someone available during all hours of operation emphasizes how important delivering quality is for Ferriot.
George Popov, Ferriot Quality Supervisor, reviewing in-process inspection dimensional trend charts with First Shift Inspector Markeet “Angel” Bradford.
Liz: What is involved with your position and responsibilities as the quality supervisor?
George: Of course, I’m making sure our inspectors are putting quality matters first and getting the right answers to anything that they might have questions about to assure we’re delivering the highest quality end products possible. However, it’s also about giving them guidance and direction on how to perform their responsibilities, and supporting them when they run into issues on the floor, or internally, and giving them the support that they need to make sure they feel comfortable doing their jobs.
Liz: How frequently do you interface with customers directly?
George: Whenever we have customer visits, typically that's with our quality director and quality engineers. I make an effort to go out of my way to be sure I meet them, the customers, just so they know who I am, and in case they need to see me in the future. They need to know I’m accessible.
Liz: Describe what your work day is like at Ferriot as the quality supervisor.
George: My schedule is from seven to four, just so I can connect with the third shift inspector when I come in before she leaves. I'm here all day first shift, and then on second shift I also overlap with the second shift inspectors so that I can communicate with them in person, at least for part of their shift, to discuss any concerns and go over any pressing issues. I periodically check my emails to see if there's anything that I need to address immediately, what I can put on the back burner for things that are not so pressing. I always make sure to get back to everybody as quickly as I can, but also as efficiently as I can.
I spend a lot of my time looking at inspection inputs, going over any issues with the inspectors, especially with my first shift team since I'm here most of the day.
I also make an inspection round on the floor and I'm increasing that as well, just so I'm aware of what's happening out there in the molding department. I'm trying to be sure I have a feel for everything that goes on and where our quality team needs to place the most focus.
There’s also a lot of correspondence with cross functional teams, with the manufacturing department, the front office personnel, a lot of contact and correspondence with all the Ferriot engineers. I support them with issues that are occurring on the floor, helping them put out “fires” as they arise, helping them put together work instructions, quality alerts, and relaying critical information both internally and to customers. I’m the interface between the quality engineers and the inspectors. That makes up the bulk of my day.
Throughout the day, I’m also working on different quality department improvements. For example, we've moved away from an old paper system for inspection records to our online IQMS inspection. That's been a challenge, but a good one. Transitions are always painful, but we know that they can be beautiful in the end.
Liz: It sounds like you have a number of hats to wear, and it's an ongoing process of improvement, which is excellent to hear. Can you speak briefly about the advantages of that shift to IQMS you mentioned?
George: Absolutely. It's just everything can be saved electronically now, so we have ease of access to all our inspection records. We also have SPC (statistical process control) available that we chart everything now so we can see trends. That helps us tremendously with process control on the manufacturing floor. When we see a process shift on our graphs, we can alert the manufacturing personnel so that they can make adjustments and take notes—something our old paperless system did not allow us to do.
With the old paper-based system, a lot of information was just put in storage. No one really saw what was happening unless a big issue would arise. And then it could really get ugly. We still have that paper system as a backup in case our system goes down, in case we lose power, or what have you. But it was just an archaic way to document our data and our customers were noticing that. It just wasn't something that gave our customers confidence in us.
Now that we've gone electronic, it has caught our customer’s attention. They can see that, yes, we do care about quality, and we do care about the data we collect. It's not just going to be put on paper and filed away. Everything's documented, it's very visible, easy to get to for review, and I think it's just the right thing to do.
George and Quality Technician Walter Kravetz reviewing scanned model from the AICON smartScan Blue Light Scanner (by Hexagon Metrology) within Optocat software, before sending the file over for dimensional analysis in PolyWorks Inspector universal 3D dimensional analysis and quality control software.
Liz: What would you consider to be your biggest challenge on a day to day basis?
George: That would be making sure I have buy-in with our people. It is very important to get our inspectors on board with why we're making changes. I know it's been a challenge. They've been used to a paper system for many, many years. And now this change with new structure and evolving process improvements. Getting them through the transition period was a very difficult challenge. Some days are really good, and some days won't be. But we continue to get through those challenging times. I also seek advice from other people, cross functional teams, and from my director. He's been a good mentor for me.
It’s a valuable thing—learning how to deal with the challenge of transition and ongoing process improvements. If I can focus the inspectors on why we're doing this so that they can see the vision as well, hopefully everyone appreciates the resulting benefits. Right now, it's kind of hard, but we're hitting several milestones. We're understanding the system more and more each day. And I think that's obviously making it easier for them to get on board. Sure, there’s still challenges. You’ll eventually run into something you haven't run into before. We'd like to fix everything right now, or yesterday. But it just doesn't happen that way. However, we're chipping away at things each and every day and it shows in our ever-improving quality.
Liz: And I'm sure it's going to provide great value to our customers in the long run.
In Part 2, we’ll discuss one of Ferriot’s new technology acquisitions, the AICON smartScan Structured Blue Light Scanner by Hexagon Metrology, and how it is helping the Ferriot Quality Team deliver quality like never before.
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A practical way to provide design flexibility - A smart way to reduce cost
Gas assist injection molding (GAIM) is an enhanced injection molding process often applied for complex parts, large parts and parts requiring an attractive, cosmetic finish. The types of parts benefiting most from this process include:
The gas assist process is introduced at the finish of the mold filling stage while the resin is still liquid. Pressurized gas (usually nitrogen) is used in place of pack pressure from the molding machine. The pressure from the gas completes the filling of the mold cavity, forcing an even distribution of molten resin against the mold. The gas is held inside during the entire cooling phase and then is vented, leaving a hollow void. For internal gas-assist molding, the void is inside the plastic. For external gas assist molding, the void is on the outside surface, typically the back side of a part.
Benefits? There are many.
The gas-assist process gets results when part design elements make the part difficult to manufacture using straight injection molding. GAIM allows for more design flexibility while still being able to provide these benefits:
Design Advantages with Gas Assist
1. Complex Designs
For the design engineer, using GAIM expands design options and helps to minimize design changes to make the part manufacturable using injection molding. One of the greatest benefits is the ability to produce complex parts. Oftentimes with straight injection molding, parts having different wall thicknesses are molded separately and assembled later.
GAIM allows multiple parts to be combined into one, reducing the need for secondary assembly processes – even if the parts have different wall thicknesses. This is because gas-assist allows heavy wall sections to intersect thinner ones. Support ribs and bosses can achieve tighter tolerances and be designed larger without fear of sink marks. Gas channels are directed toward these areas and the consistent pressure during the cooling phase eliminates sink marks, associated with these support features, on the front side of the part.
2. Metal Replacement
Gas-assist allows production of thin-walled components that have solid but hollow areas. The resulting strength and lightweight part can often replace metal fabricated or die cast parts, and reduce product cost.
3. Large parts
The introduction of gas pressure aids in mold filling, providing uniform pressure throughout the part that lasts through the cooling stage. The result is a part with less shrinkage and reduced warpage. Part weight can also be reduced by creating hollowed out areas.
4. Cosmetic finishes
Where an attractive finished surface is required, gas-assist prevents sink areas which eliminates or at least minimizes secondary operations to improve part appearance including sanding and priming.
5. Hollow parts
The gas can create hollowed out areas within parts like handles, which decreases part weight and still provides strength.
Cost Benefits with Gas Assist
1. Extended Tool Life
With gas-assist, lower clamping force is required because lower pressures are used. This results in less mold wear extending the life of the tool.
2. Less Energy Cost
With lower clamping force required, larger molds can be used in smaller presses. Smaller presses consume less power and help to decrease the cost of manufacturing the part.
3. Less Machine Time
A more rapid cooling period helps to reduce cycle time which in turn lowers manufacturing expense per part.
4. Lower Material Cost
Less material is used to produce the part because hollow areas inside of the part are created with the gas and with less resin used, part cost is lowered.
5. Quality Results
With gas-assist injection molding, the process is typically easier to control than conventional injection molding. A dependable, repeatable process provides consistent production results and less waste.
Gas Assist Tool Design
If you want to achieve high quality results, make sure you get the tool design right.
Regardless of what injection molding process will be used, it is important to engage your molder during the early stages of part design in the design for manufacturing (DFM) phase. Tooling cost, timeline and resulting part quality will be directly impacted by the quality and efficacy of the tool. When determining the optimal way to mold a part, engineers will consider all product requirements including application, resin selection and cost considerations. Mold flow analysis is used to find design constraints so that adjustments can be made. When the tooling engineer determines gas-assist is the best solution, the tool will be designed with gas channels built in to the mold that will allow the addition of nitrogen gas during the molding process. Determining your molding method early will conserve tooling cost and help to maintain project timelines. Getting your molder involved early will be critical to a cost effective, high-quality product.
To learn more about this process or to receive assistance with your project, contact Ferriot.
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COVID-19 has drastically changed the way that companies are run – possibly for years to come. Here in Ohio, we’ve all had to change the way that we work and go about our lives.
While stay at home orders are starting to slowly lift, that doesn’t mean a quick jump back to normal. As an essential business, Ferriot has remained open during the quarantine, making critical parts for the medical, industrial and financial services industries. However, it’s how we all protect our workers that’s equally as important to fighting the pandemic.
As businesses start to open back up again, Ferriot is focused on safety, both for the health of our team and for the well-being of our community. By closely following the guidelines and recommendations set forth by the leading health experts, we can work together to resume business the safe and smart way. The right way.
For over 90 years, Ferriot has always made certain to protect the lives of our workers. Now more than ever, with over 140 employees, we are committed to keeping our people safe. From canceling employee gatherings to increasing our efforts in free worker resources and our employee assistance program, we don’t plan on letting up on our updated safety policies until the pandemic is over. Other company-wide efforts include:
It’s these kinds of policies that put our workers first, so that they can have the security and peace of mind to focus on making essential medical parts, including one that is currently being used in rapid diagnostic devices that will test for antibodies of COVID-19. We’re proud that not only can we help support public health with these critical pieces of medical equipment, but that we can start that initiative here at home. This kind of mindset is what we were founded on, and what we promise to continue in these difficult and uncertain times.
In addition to these efforts, we are also doing our best to help out others in need and those on the front lines of the COVID-19 response:
After making sure that everyone on our team was properly equipped with preventative gear, we were able to supply the Akron Fire Department with over 100 N95 respirators to use as they work hard to keep us all safe.
Ferriot was also pleased to be able to help out a service provider in personal way. Because we added additional cleaning services in the office during the day, our office staff was able to meet a member of our cleaning crew. Employees got used to seeing her around and noticed her intently working on her phone. The staff found out she was taking her online classes with her cell phone because she did not have a computer at home. We were in process of replacing some computers and wanted to give her one. Our IT staff repurposed a computer for her to use at home.
These kinds of acts are something that any business can do, no matter their industry.
We are doing all of this to make sure that safety is our top priority. There is nothing more important than the health of our workers, our community, and our families. Period.
From everyone on Ferriot team, we hope that you and your loved ones are staying safe.
For more information on how to protect yourself and those around you from COVID-19, please refer to these guidelines from the CDC.
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Since 1983, I have made my career and fed my family by being that most misunderstood and maligned of professionals – a “salesman.” Except for a seven-year stretch when I worked in an office in Midtown, I have worked from a home office.
During happier times, I used to get a lot of, “What is on TV now?” being asked at 10 a.m. I reply, “Watch out what you wish for. When you work out of your house, you are always at work.” That usually shuts them up.
Read the full article at Cleveland.com.
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Team Ferriot recently enjoyed a visit from students at Akron's NIHF STEM High School. The students toured our 200,000-square-foot office and manufacturing facilities to learn more about the latest manufacturing processes, technologies and varous injection molding career opportunities from engineering design to quality management. The following photo blog provides you with a glimpse at their tour.
Ron Pack, Manufacturing Engineer, provides students with several new technology demonstrations, including collaborative robots (cobots) that assist with repetitive tasks and allow employess to do more complex work.
Students controlling the cobot using hand held touch screen. In this case, the cobots handle the repetitive task of moving the two parts to the ultrasonic welder (not visible in the photo). This permits employees to focus on tasks requiring more "brainpower."
In the color lab at American Original Building products, Mona Melton, Quality Technician, takes the students on a tour of the quality inspection area. Special software is utilized to check color samples from production runs of injection molded shake siding for homes.
Mona discusses siding features and color inspection with the STEM school students.
Numerous Engineering Services including Design for Manufacturing (DFM) and product design assistance are discussed. Here the student is looking at the 3D images of an injection molding tool design.
A STEM student studies a part with the advanced CAD software used by our Engineering team.
Marc Keeler, General Foreman, discusses several finishing operations in the paint finishing area.
As part of a Total Quality Management (TQM) exercise, students work with Quality Supervisor, George Popov, measuring parts to determine if the parts are within specification tolerance.
Aaron Dadisman, Molding Manager, explained how the molding process works, beginning with the resin pellets, emphasizing how important resin selection can be to the final product.
Aaron Dadisman further explained the molding process at one of the larger presses.
Walter Kravetz, Quality Technician, demonstrates the scanner technology used to ensure parts meet design specifications as parts of Total Quality Management (TQM).
Walter demonstrates how a CMM machine (coordinate measuring machine) measures the geometry of a part.
Dale Leopold, General Manager, spends time with students In the product testing area, where students are given the opportunity to give siding from American Original Building Products a rough time.
Student participates in an impact test to determine if siding strength meets specifications.
Training is an ongoing process for anyone choosing a career with Ferriot. Students were given an opportunity to ask the Ferriot experts questions about injection molding, engineering services, and other career paths.
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This past week, Ferriot enjoyed a visit from students at Akron’s NIHF STEM High School where students had the opportunity to learn how things are made and to see what a potential career in manufacturing looks like. Guided by Ferriot employees, students toured the facility and received a hands-on experience while learning about technologies used in manufacturing.
According to President, Craig Ferriot, “The campus visit by NIHF students last week was both exhilarating and rewarding for all our associates. Everyone here took great pride in sharing what they do, as well as highlight some of the advanced technology they work with every day. The students were interested in finding out what types of products we make and how they’re made.”
"By the look on their faces, I thought we were highly successful in dispelling the many rumors around how a career in manufacturing is anything but the dirty, greasy and nasty unskilled environment they may have thought it was,” Ferriot stated. “In fact, they found out just how technically advanced some jobs really are because of the integration of different types of highly automated equipment, robotics, computer aided design and analysis software, error detection systems, scanners and testing systems utilized in the manufacture of products today.
“In many ways, this event enabled our employees to convey their passion in such a way that these young professionals could understand and connect on a different level with today’s environment in manufacturing.” Ferriot concluded, “Our goal, is to help shine a light on manufacturing in such a way that young people are better informed, comfortable and energized to someday seek careers in manufacturing right here in Akron, Ohio.”
The Ferriot Team commented on the experience:
In our next blog, we'll share several photos of the STEM school student's tour of Ferriot and share some additional information on the processes and technologies they had a chance to see firsthand.
Learn more:
[post_title] => Cool Injection Molding Careers in Manufacturing: STEM School Tour of Ferriot [post_excerpt] => Akron’s NIHF STEM High School students visited Ferriot to learn about career paths related to Injection Molding. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => cool-injection-molding-careers-in-manufacturing-stem-school-tour-of-ferriot [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:12 [post_modified_gmt] => 2024-03-11 20:11:12 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-cool-injection-molding-careers-in-manufacturing-stem-school-tour-of-ferriot/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [43] => WP_Post Object ( [ID] => 2346 [post_author] => 3 [post_date] => 2020-02-28 19:19:00 [post_date_gmt] => 2020-02-29 00:19:00 [post_content] =>
Here at Ferriot, an increasing number of our clients are expressing growing concerns over the Coronavirus crisis and the impact of this crisis on the global supply chain. The situation remains very volatile, changes daily, and continues to have a global impact.
This affects injection molding because the industry relies heavily on Asia, especially China, to manufacture a significant portion of the tooling. A large percentage of plastic parts are molded there as well. The lower labor cost has allowed Asian countries to deliver tooling at a lower cost and provided OEMs with a reasonably safe supply chain.
Because this pandemic began in China, the Coronavirus crisis is causing production disruptions and serious shipping delays—some beyond 12 weeks. Many manufacturers and OEMs are struggling to keep their supply chains moving. Companies don’t know when workers will return, when plants will be running again and when parts will be made.
The supply chain from Asia to support US manufacturing has become a big question mark.
As a trusted American manufacturer based in Akron, Ohio, Ferriot provides an alternate solution to manufacturers that will keep production going:
If you're realizing that it's time to place the production or assembly of your key parts with another company, you'll want the transition to go as smoothly as possible.
To get you started, download our guide, "5 Key Considerations When Transferring Molds to a New Custom Injection Molder" to learn how to:
Click the button to get your PDF checklist.
Don’t wait for the crisis to get worse. Consider transferring your tools to Ferriot. We’re here to help smooth the transition and keep your production lines running.
Contact Us today if you have any questions or need additional information.
[post_title] => Stop Coronavirus Impact On Your Supply Chain [post_excerpt] => Coronavirus concerns impact injection molding because of industry reliance on China manufacturers. Keep supply chain running. Consider transfer tooling. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => could-the-coronavirus-impact-your-supply-chain [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:12 [post_modified_gmt] => 2024-03-11 20:11:12 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-could-the-coronavirus-impact-your-supply-chain/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [44] => WP_Post Object ( [ID] => 2350 [post_author] => 3 [post_date] => 2020-01-15 14:55:00 [post_date_gmt] => 2020-01-15 19:55:00 [post_content] =>Truth be told, although Ferriot has been around for close to a century accumulating an unlimited wealth of experience and applied expertise, we've really only been blogging for a short time. However, since 2020 marks the start of a new decade, we felt it was apropos to share our TOP 10 injection molding blog posts. The front-runners are determined by you, our frequent readers, after nearly 20,000 views of dozens of blog articles on a variety of topics. The majority of these articles are a quick read, requiring only a few minutes to consume. No doubt you'll find them quite valuable. You be the judge...
Decorative metallic coatings allow plastic parts to function as lightweight, economical alternatives to metals in a variety of applications (i.e. automotive, appliance, business machines, etc.). One such process is electroplating, which provides a high-quality, durable finish to plastic. Today, plating grades of ABS and PC ABS meet the stringent performance requirements of automotive and appliance applications.
This article focuses on two important front end processes, plastic part design and injection molding specifically for electroplating. Both significantly influence the success when plating a plastic part.
Read more...
Are you looking to design, develop, or produce a component that needs to be injection molded to complete the project? Do you know what key aspects you need to identify as you go to design molded plastics? When going into this process, you need to identify both the obvious and not so obvious! Below are 7 items for you to consider before launching your project.
Read more...Today, so many different parts are being injection molded. These parts include laptop and mobile phone cases, medical and military electronic components, and a variety of other materials across industrial, consumer and specialty markets. Because of this, EMI and RFI shielding is becoming increasingly important. Proper shielding for injection molded component parts is necessary to meet regulatory requirements as well as ensure continued, reliable performance.
Read more...
When beginning the process of developing a plastic component through the injection molding process, one of the top priorities needs to be identifying the type or types of resin to be used on the product. While there is opportunity to customize the resins to fit the end use of the part, there are a wide variety of resins available, which opens up unlimited possibilities in design and function.
The first step in the process is to identify the key physical attributes that the end product requires. Below is a list of properties the need to be evaluated...
Read more...When I initially joined the building products industry in 1999 there were 30+ manufacturers of vinyl siding. Fast forward to today, and it’s now down to 9, mostly through consolidation. It remains the #1 choice for exterior cladding across the US, primarily due to its low cost and maintenance freedom. And it looks EXACTLY like it did in 1999. Nothing has changed. People have been driven to this product over the years because it was the closest thing to resemble wood, without having to paint it, stain it, or maintain it.
GOOD NEWS! You have an alternative… Injection Molded Polypropylene Siding, and here are 5 reasons why it's better than vinyl...
Read more...Pad printing is an innovative and effective process for transferring a two-dimensional image onto a three-dimensional surface. It can also be a delicate process with numerous variables that can lead to an unsatisfactory image transfer if done incorrectly. My goal in this post, assuming the reader has a basic understanding of the pad printing process, is to touch on a few of the more frequently encountered problems that cause poor image transfer and how to troubleshoot them.
In my experience with pad printing, the three most commonly encountered problems that arise while printing on a job are as follows: an incomplete print or a print featuring excessive voids, distorted and blurred prints, and the pad carrying excess ink or dirt outside of the desired image.
Read more...
Of course, we've only scratched the surface when it comes to addressing the countless questions, challenges and problems you're facing in order to complete your injection molding projects on-time, within budget, and without sacrificing quality.
Do you have a question you'd like answered but are afraid to ask? Feel free to use the form below or Contact Us and we'll be glad to get back to you. We may even feature the answer to your question in a future blog article or FAQ resource.
All of us at Ferriot wish you a happy and successful 2020!
Subscribe to the Ferriot "Plastics & Injection Molding Manufacturer" blog.
The year 2019 was a very special one for the Ferriot team, marking our 90th year in business. Wow! Ninety years! As you can imagine, we've enjoyed learning more about the colorful history and numerous accomplishments of Ferriot's early years. Many on our team weren't aware of our early history with Disney or early Star Wars toys. The year has also been full of reminiscing over family, friends and business associates that have come and gone through the nine years of our existence. It's only fitting to recap some of them by sharing the following 90th anniversary posts from the past year.
Full-service custom injection molder of engineered resins
pays tribute to its long history, with an eye on a bright future
On June 11th, Ferriot began a year-long celebration of its rich 90-year history with a special event for employees at its Akron, Ohio facilities.
Privately held since its founding in 1929, the company spans over five generations of the Ferriot family. In 1999, Ferriot Inc. expanded to its current 200,000-square-foot office and manufacturing facility at 1000 Arlington Circle in Akron, Ohio.
Read more...Company History Highlights by Gene Ferriot (1916-1970's) from steel engraving to injection molded plastics, from Disney characters to Polaroid aviator glasses – a nostalgic look back
In 1916, I started working at the Die Sinking and Machine Company, a machine shop started by my father, grandfather and uncle. I was joined a year later by my brother Glenn. I learned the steel engraving trade and Glenn learned the machinist trade.
After several years we both left to work for the Mechanical Mold and Machine Company, which had been started by four of my father’s former employees. In 1924, I left their employment to start out on my own in the basement of my home on Storer Ave. My brother Joe, who was still attending high school, started working for me in 1925...
Read more...Craig Ferriot’s Speech at 90th Anniversary Event for Employees on 6/11/19
Celebrating 90 Years of Excellence in Building Ferriot’s Future
This is our 90th year celebration. I can't believe it. I've been here a third of it. 33 years! And over the last couple of weeks, I've taken the opportunity to go back and look at some old literature, and I was able to get a lot of information from my dad, my grandfather and some others. I was reminded of all the things that took place at Ferriot that made it successful.
Read more...Our 90th anniversary celebrations continue as Ferriot is the featured story on the front page of this week's Plastics News magazine! Here's an excerpt from the article written by Don Loepp, Plastics News editor.
Akron, Ohio — If you geek out over cool old plastic parts, Ferriot Inc. is worth a visit. The lobby display cases are packed with parts molded in the past seven decades, but they tell only a fraction of the story. Ferriot's full history could fill a museum. Remember hobby horses on bouncing springs? Green army men? Early "Star Wars" toys? Ferriot molded — or made the tools for — all of them. Ferriot also molded big television cabinets back when TVs were real pieces of furniture, not just oversized computer screens.
Read more...Of course, as monumental as a 90th anniversary may be, hitting a milestone like nine decades also provokes thoughts of the future. What can we do to top 90 years. Trust me, we have BIG plans to continue providing ever-expanding custom injection molding capabilities, execeptional value-added engineering services, and stellar customer support. We're looking forward to what the next decade will bring!
In our next blog, I'll share with you our TOP 10 Blog Posts of All Time.
Subscribe to the Ferriot "Plastics & Injection Molding Manufacturer" blog.
[post_title] => Recap: Ferriot's 90th Anniversary [post_excerpt] => Recap of Ferriot's 90 year history as an injection molder / contract manufacturing resource specializing in custom injection molding & engineering services [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => recap-ferriots-90th-anniversary [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:13 [post_modified_gmt] => 2024-03-11 20:11:13 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-recap-ferriots-90th-anniversary/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [46] => WP_Post Object ( [ID] => 2354 [post_author] => 3 [post_date] => 2019-12-11 13:42:00 [post_date_gmt] => 2019-12-11 18:42:00 [post_content] => Is it just me, or did 2019 fly by? Where did the year go? Although Team Ferriot has been very busy this past year, we made sure to cover a number of important topics that help our customers and soon-to-be customers achieve successful results in their injection molding projects. We've covered the gamut, from structural foam molding and custom mold design to ultrasonic welding and selecting custom resins. Below are featured the best blogs of 2019. These are the blogs our visitors, subscribers and customers have read the most in the past year. Enjoy!
When it comes to plastics manufacturing, choosing ultrasonic welding services compared to traditional welding and adhesive methods offers a variety of benefits.
In short, ultrasonic welding is faster, safer, and cheaper than other means of bringing plastic components together.
Read more...Injection molding is a tried and true manufacturing method that has experienced small, incremental changes over the years. It used to be, if you had a product or part to be manufactured, your injection molding manufacturer would provide you with a list of polymers to choose from. Your design and engineering team would work together along with the injection molding team to select a resin that would suit your needs. A variety of factors would be considered including durability, cost, flexibility and cosmetics.
Ready for a secret? It still works like that.
With most manufacturers, you are going to need to select the resin for your part from a list of available options. However, modern facilities have moved into a more advanced method of providing an option not previously available on that list—custom engineered resins.
Read more...In our next blog, I'll share with you our 90th Anniversary Recap.
Is there a challenge or problem you're facing with one of your injection molding projects? Or do you have a question you'd like to ask? Feel free to use the form below or Contact Us and we'll be glad to get back to you. We may even feature our answer in a future blog article. Subscribe to the Ferriot "Plastics & Injection Molding Manufacturer" blog.
[post_title] => ICYMI: Ferriot's Best Injection Molding Blogs of 2019
[post_excerpt] => Our top blogs on achieving successful injection molding projects--structural foam molding, custom mold design, ultrasonic welding, selecting custom resins.
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[post_content] => When it comes to plastics manufacturing, choosing ultrasonic welding services compared to traditional welding and adhesive methods offers a variety of benefits.
In short, ultrasonic welding is faster, safer, and cheaper than other means of bringing plastic components together.
Read on to learn more about what ultrasonic welding is, how it compares to traditional methods and some considerations you should take before selecting a plastics manufacturer.
Ultrasonic welding is the process of converting electrical current into high-frequency ultrasonic vibrations. Those frequency vibrations move so fast that it causes a friction which melts materials together to create a solid-state weld. This process is frequently used for plastics but can also be applied to some metals.
Ultrasonic welding plastic typically takes mere seconds from part insertion to part removal from the ultrasonic welding machine. Other methods of welding require the manufacturer to spend much more time, which also means a higher cost for power and/or fuel. More time is needed to reach higher temperatures for welding, and to allow the part to cool. With adhesives, parts will also need to cure for an additional amount of time compared to ultrasonic plastic welding.
The key downside is that the ultrasonic welds will have a depth of less than a millimeter. So, that means it is not practical in industrial or commercial instruction. However, it’s ideal for manufacturing components in various markets including consumer goods, military electronics, medical devices and more.
When evaluating a plastics production method, risk factors are important to consider. For example, with traditional welding requiring higher temperatures, you have the risk of an open flame and flammable fuels. Also, those fuels and adhesives can create toxic fumes. This means a few things. First, added risk for the manufacturer’s employees. Second, the added cost of additional training, personal safety equipment (PSE) and facility safety precautionary measures.
The high frequency produced by the machine is one key safety concern when using the ultrasonic method. This could potentially damage someone’s hearing, but this risk is simple to mitigate and much less dangerous than risks posed by other welding methods. An ultrasonic welding machine can be placed within a safety cage and workers are required to wear hearing protection.
Overall, when it comes to manufacturing plastic components, it’s easy to see why ultrasonic welding is the preferable option.
Are you working on a project that would be well-suited for ultrasonic welding? If so, please schedule a consultation to learn more about Ferriot’s contract manufacturing services. Or, download our worksheet on Plastics in an Industrial Setting by click on the below image.
Learn more:
Injection molding is a tried and true manufacturing method that has experienced small, incremental changes over the years. It used to be, if you had a product or part to be manufactured, your injection molding manufacturer would provide you with a list of polymers to choose from. Your design and engineering team would work together along with the injection molding team to select a resin that would suit your needs. A variety of factors would be considered including durability, cost, flexibility and cosmetics.
Ready for a secret? It still works like that.
With most manufacturers, you are going to need to select the resin for your part from a list of available options. However, modern facilities have moved into a more advanced method of providing an option not previously available on that list—custom engineered resins.
Advances are being made relatively frequently in polymers and resins. This is one area where science and technology continue to improve. But, when there are literally hundreds—even thousands—of resins available, why would you need something beyond traditional choices? Read on to learn why developing a custom engineered resin may be the best, most cost-effective way to manufacture a product.
At first, it might seem that selecting a custom engineered resin would cost more than going with a readily available option. While there will certainly be an upfront cost that you would not otherwise incur—the cost to research and develop the resin, this is a one-time fee.
With all the various features to consider when it comes to resins including ductility, rigidity, dimensional stability, temperature tolerance, chemical resistance and more, there are many variations and trade-offs. You might find what appears to be the perfect resin for your product, but it may be in limited supply or material costs could be high.
By developing your own resin, you are better able to control the supply and cut out the frustration of dealing with additional suppliers and middlemen. Also, it may also be possible to have the resin developed in closer proximity to the injection molding plant. This means you may cut down on supply and transportation costs associated with a project.
What if you don’t need all the features of a more expensive resin, but you need an enhanced rigidity? Working with a manufacturer that can custom engineer resin solutions can help meet your needs and save money, especially when you’re dealing with large and potentially repeated production runs. Why pay for features you don’t want?
As previously stated, there are already a lot of options available when it comes to resins and polymers for injection molding. However, certain applications have very specific needs. When designers and engineers are working to produce a part that your business depends on, getting everything right is critical.
With existing resins, you may end up making trade-offs. One resin may have the ductility you are looking for, but may not be electroplatable. Luckily, customized resins can give you everything you need for your specifications.
What if your project has requirements that no one else has brought forth before? That is a case where you would want to work with a resin specialist who can create a resin that fits your product. It’s also important to note that this unique mix may be created just for your company but it could become available to anyone. So, always check contracts, especially if you are concerned with trade secrets.
In manufacturing it comes as no surprise that parts, components and mixtures can vary greatly over time. If you are relying on a specific company for your resin, you are, in a way, at their mercy. If they have production issues, you will have production delays or other problems.
By developing a proprietary resin compound, you have more control over your supply. This may mean working with additional manufacturers to produce enough resin for your projects. It might also mean working to ensure that your resin mixture can continue to be manufactured, even if another company falters or discontinues a resin, filler or modifier. There are a number of sources for base resins and compounding services available. Resin manufacturers may make small changes over time that offer a similar or comparable product, but it is not always the same. If you want the highest level of consistency, you need to be in control of your own resin.
Ferriot, Inc. can work with you to make sure you have the best possible resin for your project. If the resin does not already exist, we will help you create a proprietary resin solution. We understand the demands of high production injection molding for a variety of industries including aerospace, automotive, and medical devices and we will go to great lengths to make sure that your product is the best it can possibly be. Schedule a consultation today to learn more about custom engineered resin or click on the image below to download our workbook on selecting the right resin for your project.
Learn more:
Our 90th anniversary celebrations continue as Ferriot is the featured story on the front page of this week's Plastics News magazine!
Here's an excerpt from the article written by Don Loepp, Plastics News editor.
Akron, Ohio — If you geek out over cool old plastic parts, Ferriot Inc. is worth a visit.
The lobby display cases are packed with parts molded in the past seven decades, but they tell only a fraction of the story. Ferriot's full history could fill a museum.
Remember hobby horses on bouncing springs? Green army men? Early "Star Wars" toys? Ferriot molded — or made the tools for — all of them.
Ferriot also molded big television cabinets back when TVs were real pieces of furniture, not just oversized computer screens.
"Over the years, I think what's really kept the company in the mainstream and relevant is the fact that it's forced to reinvent itself every so often," Craig Ferriot said in a recent interview at the plant.
"We have continued to be innovative, and take the ideas of the past ownership and build on those, and take the original principles of our founding fathers, which was to develop relationships with customers, and how valuable that is," he said.
He's the president of Ferriot Inc., a family-owned injection molder in Akron. The company is 90 years old, but he's just the third generation of Ferriots in the business.
You can read the full article here.
Learn more:
Craig Ferriot’s Speech at 90th Anniversary Event for Employees on 6/11/19
Celebrating 90 Years of Excellence in Building Ferriot’s Future
This is our 90th year celebration. I can't believe it. I've been here a third of it. 33 years! And over the last couple of weeks, I've taken the opportunity to go back and look at some old literature, and I was able to get a lot of information from my dad, my grandfather and some others. I was reminded of all the things that took place at Ferriot that made it successful.
We are here in celebration of what we have achieved together. Without you guys, it wouldn't be possible. Without the people that preceded us, it wouldn't be possible. Without our customer's loyalty, it wouldn't be possible. It wouldn’t be possible without the suppliers that we deal with, your families, who put up with you working every day and doing some things above and beyond. You do that every day, without exception and we appreciate it. So really, this day is for all of you. It is for everything we built together and more importantly, the future and what we could build for the next 90 years.
One of the key things to our success is people. You are the folks that make us successful. And one of the things our founding fathers always said is, “dream big, achieve big.” That is something they lived every day. They didn't settle for conventional. They wanted to solve major problems. I would like to take a moment and share a little bit about Ferriot and our history.
We had some pretty remarkable founding fathers going back seven generations. After coming to the Akron area to work for Goodrich, family members created several businesses and from Ferriot spawned about six different companies in Akron all based around mold making, die sinking and engraving.
Our name was synonymous with our people's talents and what we were able to deliver to our customers. Our customers would have an idea, a sketch and bring it to us. These gifted artisans and craftsmen would take that idea and turn it into a product. They were actually responsible for not only helping to develop and design that product, but how it all fit together and how they had to market it.
There are the three things that stick with me today; that's appreciation for people, pride in our workmanship and what we deliver to our customers, and remembrance. Remembrance of those who came before us and everything that they were able to accomplish and build as a foundation for all of us to enjoy. We're writing our new chapters right now. The key is keep dreaming. Don't settle for something less. Don't be conventional. Don't be discouraged if you make mistakes; that's how we learn. So with that, I'd like to thank everybody for the last 90 years in celebration of what we've accomplished together.
So I appreciate it. Give yourselves all a round of applause.
Learn more:
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Here at Ferriot, we’ve been proud to be a leader in thermoplastic injection molding since the 1940s. Our clients turn to us for professional assistance with contract manufacturing, custom injection molding, painting and assembly. Structural foam molding is another capability we offer when traditional injection molding may not meet part design requirements. The structural foam process creates parts with a high strength-to-weight ratio and is often used for large parts and in metal to plastic replacement.
Traditional injection molding is typically done in two stages. There’s an injection stage where melted thermoplastic is injected into a mold, and a packing stage where pressure is built and the plastic is formed into the shape of the mold. In structural foam molding, the injection stage is basically the same, but the packing stage is augmented by a chemical blowing agent mixed with the material. That chemical blowing agent is triggered by heat and expands the material by creating a microcellular structure at the core with an integral outer skin.
A part built using structural foam molding offers a number of advantages that include:
Structural foam parts generally weigh less and aren’t as dense as similar parts manufactured using other processes. The actual weight savings can vary, but parts built using structural foam molding can be 10% - 30% lighter than other parts. The integral skin contributes to added strength and the entire process creates parts with low stress.
Structural foam molding also scales well, allowing large or bulky parts to be manufactured while still retaining the superior production speed offered by injection molding. Regardless of size, structural foam parts are able to be worked post-production in a manner similar to parts constructed of wood or metal. The surface of a finished part is smooth offering the potential of easy cleaning, and can be painted over.
An additional benefit to parts manufactured using structural foam molding is part durability. As a result of the difference in process, parts built employing structural foam molding are sturdy while remaining rigid, and possess greater internal flexibility than parts built using traditional injection molding.
There are many ways to achieve cost savings when considering structural foam:We’ve been busy putting structural foam molding through its paces to build a variety of parts, including gas pump front fascia. Results have been everything we could have hoped for. Along with the durability offered by the new parts, the material options available for structural foam molding also means a finished product can be chemical resistant, offer electrical or thermal insulation, and can be developed for outdoor applications.
Think structural foam molding is an alternative solution for you? We encourage you to contact us to discover how structural foam molding can benefit your business.
Learn more:
Company History Highlights by Gene Ferriot (1916-1970's) from steel engraving to injection molded plastics, from Disney characters to Polaroid aviator glasses – a nostalgic look back
In 1916, I started working at the Die Sinking and Machine Company, a machine shop started by my father, grandfather and uncle. I was joined a year later by my brother Glenn. I learned the steel engraving trade and Glenn learned the machinist trade.
After several years we both left to work for the Mechanical Mold and Machine Company, which had been started by four of my father’s former employees. In 1924, I left their employment to start out on my own in the basement of my home on Storer Ave. My brother Joe, who was still attending high school, started working for me in 1925. In 1926 I moved to a small shop on Yale Street previously occupied by Freitag. My brother Bert joined me and a little later Glenn came to work with me. We continued operations at this plant until 1932, when we moved to Miller Avenue where we took over the operation of the Wadsworth Core Company which had run into financial difficulty. A number of the Wadsworth employees were put on our payroll and one of them was Jerry Evanitcka. At this time, Ferriot Brothers had about 25 employees, Roy Christenson was also one of them. We continued the manufacture of core machining and repair parts along with core plates and other items used in the foundry trade. At this time, our business was molds and equipment for the rubber industry.
We were the first to make pressed aluminum cavities used in the making of molds for rubber dolls and blown rubber toys of all kinds. Our customers for these molds were all of the doll manufacturers. We built hundreds of molds for the Shirley Temple, Diana Durbin and Didee dolls, and molds for all of the Walt Disney characters. Along with this, we invented and built many machines used in connection with the molding of these parts, and Jerry and Roy were involved in the machining and assembly of these machines during our years at Miller Avenue.
We expanded and prospered even though we were severely hurt during the depression years when all of our working capital was held up for many months by the bank holiday. It was during this period that my brother Bert left us to seek greener pastures on the west coast where he became very successful; he is now retired.
Our lease on the Miller Avenue building, owned by Brown-Graves Lumber, was for 10 years and in 1941 we decided to move to new quarters where there was more room for expansion. We purchased our present building from the City of Akron who had used it for a number of years as the city workhouse. The move meant working in both plants for a number of weeks. As machines were moved, they were converted from overhead line shaft and belt drives to electric motor drives which also meant the installation of bus bar and transformer and switching equipment. We continued in the machining of molds and machining for the rubber industry and added a foundry building which we equipped with gas for crucible melting and later with electric furnaces. We revised the art of making mold cavities using investment cavities progressing from tombasil and nickel bronze to beryllium copper. At one time, we were the largest users of beryllium copper. We developed a line of proprietary items including rotary files, air motors, filters and machinery and rubber presses that were sold under our Power Max label.
During the second world war, all civilian production stopped and we converted to war work, much of which required building the machines used in the production of these new products. We were the largest producers of cartridge dies for small caliber bullets. We machined thousands of tank treads for the Cadillac tank and the amphibious tanks. We made hundreds of oil burners for the Victory and other ships. We machined many parts for the Goodyear Aircraft and other plane manufacturers. I believe we made all of the molds for molding gas masks for the Armed Services, the Navy and a civilian type. We also made molds for the rubber frames for the Polaroid glasses worn by the aviators and many other war related items.
It was during this period that we were hit by a destructive tornado, followed by several days of hard rain storms. We lost most of our roof and had to replace most of the windows. Because of the extreme shortage of labor, it was necessary to make all repairs with our own employees. The resulting clean-up of the plant, machines, work in process, and the rebuilding of the roof and windows, meant many hours of hard work and a herculean effort on the part of everyone. Fortunately, we were able to resume production in a very short time.
After the war we rapidly returned to civilian production, and a gradual change was made from molds for rubber to plastics in the upcoming plastics age. We added a building and started molding plastic by the injection molding process. The first five injection molding machines we built in our own shop which were all of the hydraulic type and Jerry handled most of the the hydraulic work on these machines. We continued the production of molds for toys, and by now they were made almost entirely of plastic. At one time, we had a proprietary line of plastic toys and figurines and several other novelty items.
As our business grew in the plastics field, we gradually disposed of some of our operations such as rotary files, air motors, machinery and presses for the rubber industry and all proprietary items to other companies either thru outright sales or leasing.
In 1952, we hired Chuck Strayer for the drafting department. About this time, the plastic toy molding manufacturing was expanding rapidly, especially those relating to the movies and television. This required the making of hundreds of models and Joe spent many hours both here and at home, and at the same time taught a number of young men the art of model making.
As you all know, Joe was a fine sculptor and a master of all kinds of art. For his contribution to fine arts, he was awarded the world’s highest honors by the Queen of England in an award given to very few men in this country. I am very proud to have started Joe on his artistic career. In our early years, I worked with him in making the models for the dolls and Walt Disney characters. Chuck worked closely with Joe in design work and finding and servicing outside sources of model making.
At this point, I would like to give my brother Glenn recognition for all of the ways in which he contributed to the growth of this company. He contributed a great deal to both the building of molds and machines, and to the expansion of the plant and operation in general. All of you who have worked with him know how of the success and growth of our company he contributed.
Everyone here has been with us 20 years or longer and are familiar with all the changes that have taken place these past 20 years. The changes are continuous in products and in customers and methods. As I wrote this, I was reminded of all the things and events that have transpired during my lifetime. I can remember the real horse and buggy days and the one room school house and how everyone used to run outside to watch one of the new-fangled automobiles go by. It is hard to believe all the changes that have occurred in one lifetime and in the growth of this company over the past 60 years.
Well, enough of the past, what we should all be concerned with now is your future. There will be new markets, new customers, products, methods, machines, talent and growth and it is your opportunity to make it work toward a rewarding and prosperous future for you, your family and your company. This holds true for all of our newer employees also, and it is up to every one of you to help them in every way possible to make a better life for them, their future and their company.
I enjoy being with you and talking to you and hope I can continue for many years. I will be especially interested in seeing what you can accomplish in the future.
In conclusion, I would like to leave you with this one thought. It is very hard to lose old employees and friends. We will miss them, but never forget them, and will be forever thankful for what they were able to contribute to the growth and future of your company.
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[post_title] => Molding History: “Forever Thankful for What They Were Able to Contribute” [post_excerpt] => Gene Ferriot shares his recollections of the company's first 60 years and the people that helped make Ferriot a premiere injection molding manufacturer. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => molding-history-forever-thankful-for-what-they-were-able-to-contribute [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-molding-history-forever-thankful-for-what-they-were-able-to-contribute/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [53] => WP_Post Object ( [ID] => 2369 [post_author] => 3 [post_date] => 2019-07-02 14:49:00 [post_date_gmt] => 2019-07-02 19:49:00 [post_content] => Full-service custom injection molder of engineered resins pays tribute to its long history, with an eye on a bright future On June 11th, Ferriot began a year-long celebration of its rich 90-year history with a special event for employees at its Akron, Ohio facilities. Privately held since its founding in 1929, the company spans over five generations of the Ferriot family. In 1999, Ferriot Inc. expanded to its current 200,000-square-foot office and manufacturing facility at 1000 Arlington Circle in Akron, Ohio.
Although the name may not be immediately recognized, Ferriot Inc. manufactures products that the American consumer sees and touches every day—from ATM machines and gas pumps, to medical devices, jet skis and robots in retail stores. Ferriot also participates in the building products market through its wholly owned subsidiary, American Original Building Products. American Original manufactures a proprietary line of shake shingle siding.
Over the decades, buyers of plastic parts for medical equipment, business machines and industrial applications have learned to rely on Ferriot for their vast engineering experience. Collectively, the Ferriot team has nearly 1,500 years of experience in the injection molding business. Today, the company includes over 150 employees, with an average tenure of 10 years; with 34 people who have over 20 years of service, and 13 people with more than 30 years of service. The longest tenured employee, Bob Hoskin, has been with the company almost 46 years.
“Ferriot has experienced exceptional double-digit growth over the past several years by reinvesting in the business with new machinery, technology and talent,” said company president Craig Ferriot. “We’ve been successful at evolving and changing to stay ahead of other injection molders in the industry. We will continue to position ourselves in the most competitive ways possible to engage with and support our growing list of global clients.”
Ferriot continues, “Moving forward, our focus will remain on investment in infrastructure and new technologies that expand our capabilities and permits production of more complex products. Our continued commitment to the longevity of the company includes growing our engineering staff which allows us to expand upon our tool design expertise that helps bring our customer’s new product ideas to life.”
One example is the installation of the Negri Bossi BI-POWER VH2000-22500 press last year. “This is part of our long-term commitment to increase efficiency, boost labor productivity, simplify workflow, and ultimately deliver the highest quality plastic parts to our customers within budget and on time,” says Ferriot.
Throughout the 90th anniversary year, several events will be held for employees as well as the local community including various academic institutions and community outreach programs.
See the Ferriot 90th Anniversary page here. We'll add new stories and photos to this page throughout the year-long celebration.
[post_title] => Ferriot Celebrates 90 Years as “Your Partner in Plastics”
[post_excerpt] => Ferriot, a full-service custom injection molder of engineered resins pays tribute to its 90 year history, with an eye on a bright future.
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Plastic injection molding is perhaps one of the most popular forms of manufacturing today. Engineers and manufacturing companies from virtually every industry around the world have found that using injection molding to manufacture their products is one of the most cost-effective ways to go.
Cost effectiveness is not merely limited to the initial materials and machining costs, though. Other considerations have a direct effect on this claim including plastic part durability and longevity, customer and client satisfaction, part tolerances and overall labor costs. Read on to learn more about the top 7 benefits of working with an injection molding contract manufacturer.
Injection molding can be used in a wide range of projects. From simple components to parts that have complex geometry and detail, injection molding enables manufacturers and engineers to develop a variety of different parts that are more difficult to make using other molding and machining processes.
The liquid nature of heated thermoplastics and the amount of pressure applied to the resins and molds allows for a high level of detail to be integrated into the molded component. Trying to manufacture parts with the same high level of detail and complexity through other means of manufacturing can be both expensive and challenging.
Once the mold, commonly referred to as a “tool”, is complete, you are ready to produce parts. Injection molding is perfect for mass producing parts as the time to mold a part can be as short as 15-30 seconds. In addition, a multi-cavity mold can produce multiple parts at once or family molds can produce two different parts at the same time, for example the top and bottom of an enclosure.
Most injection molding machines are automatic. They’re programmed for optimal pressure and cool time for each tool. This means that injection molding new parts is a streamlined, repeatable and consistent process. So, you have machines that are designed and programmed to save time, long-lasting steel tools that will allow you maximum production runs and a complete process that runs faster than other manufacturing methods. The efficiencies inherent in the injection molding process means saving both time and money.
There are a variety of standard and custom resins that you can choose for your injection molded components. Based on the needs of your particular product, you can indeed make a part that is stronger yet more flexible than with other forms of manufacturing. Fillers used in the resin mix allow the parts to maintain an increased durability while also boasting a less dense—and thus lighter weight part.
The number of choices when it comes to thermoplastics for injection molding is nearly limitless. The resins can be more or less susceptible to temperatures, chemicals and other environmental factors.
Overall, injection molding allows you to specify the properties of component material. This allows for highly customized units. It also provides parts that last longer in use and under harsh conditions, increasing the value to the consumer.
Injection molding has an advantage in that you can choose to use different types of resins simultaneously during the same molding process. This is done via co-injection molding. This process uses a three-step injection process. First, one type of resin is injected into the mold to create the outer skin or laminate. This is followed by another resin being injected into the core of the mold. Finally, the outer or “skin” resin is injected to fully encapsulate the piece.
The basic premise is that regrind or reprocessed materials serve as the inner core of a part while new resin covers the part. This way you have the same strength throughout, and an excellent outer appearance. Why do this? There are two key reasons. First, injection molding generates little waste. You are using repurposed plastic, known as “regrind” which is better for the environment. Secondly, it lowers the cost of the parts produced, because reprocessed material costs less than virgin resin.
Injection molding is a mostly automated process. That means that a sole operator can manage multiple machines. This means a lower cost in overall labor. Furthermore, while humans remain nearby to run and assist the process, computers and robots handle most of the work. With today’s advanced computer aided design (CAD) and computer aided manufacturing (CAM) software, higher accuracies and tighter tolerances can be maintained.
Another great benefit to injection molding is that it is easy to make the same part using different materials. This will result in providing different aesthetics. Smooth and high sheen plastics are available as well as those that are rough textured. The mold can be textured with the desired finish. While considering options for a part’s finish, also take into account whether the part will need to be painted. Some thermoplastics are ideal for painting while others are available in multiple colors, so painting is not even necessary.
When injection molded parts are completed, they require little to no additional work such as deburring, and other finishing touches required with other manufacturing types. While there is an initial investment in molding dies and design, this cost will be outweighed by the savings in longer and/or recurrent production runs. Instead of making thousands of parts again and again, you make the part once and are able to make copies repeatedly. It is faster and typically cheaper to go with injection molding for a wide range of manufacturing projects.
To learn how to get the most from your relationship with an injection molding contract manufacturer, download our free guide—Designing Injection Molded Parts: A Handbook for Designers & Engineers. Or, if you prefer, call us at (330) 786-3000 for immediate assistance.
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[post_title] => 7 Eye-Opening Benefits of Plastic Injection Molding [post_excerpt] => Not sure if plastic injection molding manufacturing is right for your project? For the time and money you could be saving, it’s worth looking into. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => benefits-of-plastic-injection-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-benefits-of-plastic-injection-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [55] => WP_Post Object ( [ID] => 2373 [post_author] => 3 [post_date] => 2019-04-30 12:14:00 [post_date_gmt] => 2019-04-30 17:14:00 [post_content] =>
Structural foam molding is an option available to manufacturers who are looking for a way to create stronger, more rigid plastic parts. It is also a method used to reduce potential part weight for larger parts. Almost any type of resin can be used with this type of injection molding. Structural foam injection molding uses lower pressure and a foaming agent mixed in with the resin. The foaming agent expands within the resin, leaving a dense outer and inner wall with a foam or honeycomb-like center. This cellular core in the part is what contributes to the decreased part weight. During the expansion process, internal shrinkage or "sink" is reduced which creates a more uniform and aesthetically pleasing part. This process can also contribute to less internal stress in the part with better stability.
Overall, structural foam methodology provides a more economical solution than other techniques. It also provides advantages that cannot be achieved using other production processes. The process accommodates intricate designs quite well. Because of the honeycomb interior, parts manufactured using this process also exhibit an increased stiffness-to-weight ratio as well as higher strength-to-weight ratios. Depending on the design, engineering capabilities, and other variables like material choice, the overall weight of the part can be reduced by up to 20%.
Structural foam injection molds incorporate some unique properties that make them favorable. This technique often makes use of aluminum—rather than steel molds—for parts up to several hundred pounds. If they’re properly maintained, these aluminum molds can be used for runs in excess of one hundred thousand parts. So, what accounts for the longer life span? The low pressure required for the structural foam molding process minimizes wear and tear on the components. Plus, the ability to design molds with multiple gate points optimizes processing and overall tonnage requirements.
It’s hard to answer such a question without knowing the particular needs of any specific project. However, if your project’s design features certain characteristics, then structural foam may be the right solution for you. If the part is large and needs to maintain high structural integrity, this may be the right way to go.
Structural foam injection molding is good for making parts with an increased stiffness of up to four times other injection molded parts, and it can do this while decreasing the part weight. If the design requires medium-to-thick wall cross-sections, this technique could be a strong candidate for your project. If the goal is to minimize part sinks, structural foam is capable, here, too.
Check out our worksheet, “Which Injection Molding Technology Is Right for You?” to learn more.
If you’re ready to discuss your project details, contact us.
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Part 1 of this blog post discussed some important considerations for custom mold designs for injection molding projects. Topics included the impact of resin selection and mold construction materials. Now, let’s consider how the resin is injected into the mold and the impact of the wall thickness of the part.
The opening through which resin is injected while molds are clamped together is known as the gate.
The gate’s design, location, and type have important effects on the final part, including packing, gate vestige, dimensions, warping, and overall cosmetic appearance.
Two types of gates are used in injection molding: manually trimmed and automatically trimmed.
Manually trimmed gates require an operator to separate parts manually from the runners after each cycle. This type of gate would typically be selected for materials such as PVC that cannot be subjected to high shear rates, or the design requires simultaneous flow distribution across a wide front.
Automatically trimmed gates have a feature built into the mold that shears the part upon ejection. These types of gates are used to eliminate the need for manual shearing, which can help cut costs, maintain a consistent cycle time across all runs, and minimize part scarring.
Your mold’s gate design plays a major role in choosing which gate type to use. The size and shape of the component will dictate which gate designs are available for your application.
A gate’s location on the mold is important because it is crucial to providing the best fill for the application. Gates should be placed at the heaviest cross-section, which allows for proper part packing while reducing voids and sinks. Gates should be located away from cores and pins to reduce obstructions in the path of the flow. If possible, place the gate in an area where stress from the injection will not detract from overall aesthetic requirements or functionality. The gate should also be located to shorten the flow path in order to prevent cosmetic flow markings. With the addition of multiple gates, optimum mold flow can be achieved, but weld lines, also known as knit lines can become an issue. A weld line is created where two flow fronts meet and are not able to meld together. This can have a weakening effect on the part.
Keep in mind that the mold’s gates can vary in both shape and size. This is usually determined by the size and shape of the part. Larger parts require larger gates. Smaller gates provide a better appearance, but they can take longer to mold or require higher pressure for a proper fill.
Wall thickness is among the most important features of your injection molded component. The part’s wall thickness can have a major impact on production quality, speed, and cost of the final parts.
Although there is no ideal wall thickness for injection molding, as a rule, minimizing wall thickness is usually the goal during design to reduce cost and weight. Parts with thinner walls require less material and less time to cool, both of which can greatly reduce cost. Minimizing wall thickness requires taking factors like structural requirements, the specific resin being used, and the part’s size and shape into account.
A constant wall thickness is key to molding high quality parts. Thicker sections take longer to cool than thinner sections. That means thin walls are already cool while the thicker walls are still cooling, which causes them to shrink around the thinner walls. That can cause the component to warp, crack, and twist. If different wall thicknesses are necessary, make the change in thickness gradually; overall differentiation should be no greater than 10 percent. There is a trade-off however. Thin walls will require higher injection pressures and tend to be less forgiving for stresses. An experienced mold designer can help you come up with design alternatives such as using cores and ribbing.
When designing custom molds for your parts, also consider issues like draft, sink marks, textures, and parting lines. The mold draft facilitates removal of the part from the mold. The degree of draft will vary with geometry and other part characteristics including surface texture requirements. In general, the more draft the better. Sink marks occur when the exterior walls cool faster than interior ones, creating warpage or unsightly marks or adding stress to the part. These marks most commonly occur at bosses, corners, and ribs.
Considerations to eliminate sink marks include reducing the thickness of an area by coring it out or making sure bosses and ribs are no more than 60% of the thickness of the nominal wall. Parts can also be molded with a texture in the mold.
Adding textures can provide functionality or improve cosmetic appearance while hiding imperfections such as sink marks and parting lines. Every molded part will have parting lines. Given that the parting line is the easiest place for venting, melted resin will always flow toward it. Consider your application when creating the parting line. A sharp edge at the parting line will it less visible while a safety edge radius is preferable for medical applications or toys.
Keeping these things in mind when designing your custom mold and discussing them with your designers and engineers will help to ensure you achieve the most economical solution for your injection molding process.
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[post_title] => Custom Mold Design: Part 2 [post_excerpt] => Learn more about the components included in your custom mold design. What kinds of questions should your mold engineering and design team be able to answer? [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => custom-mold-design-part-2 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-custom-mold-design-part-2/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [57] => WP_Post Object ( [ID] => 2377 [post_author] => 3 [post_date] => 2019-03-06 19:40:00 [post_date_gmt] => 2019-03-07 00:40:00 [post_content] =>Designing custom molds for your injection molded products can be a complex process. However, working with the right team can greatly reduce the complexity and cost while improving the quality of the completed part and minimizing the length of the production cycle. Take the time to answer the following questions before you attempt to design molds for injection molding.
Aside from determining core function and structural features, the injection molding process itself is a factor to consider. A part’s features must be reviewed carefully in terms of how the resin material enters and fills the mold cavity, as well as how the material cools while in the mold. An experienced tool design engineer understands how to control mold temperature and cooling rate process optimization. This critical step will help to optimize cycle times, reduce stress in the part and prevent various physical and cosmetic defects. The result is a stronger part that is easier to manufacture.
Injection molding has long been the most popular method for manufacturing plastic parts. In fact, at any given moment, you can likely find several products that were injection molded, including the pen you use, your smartphone’s body, bottle caps, many types of plastic containers and housings, car components and interiors, computer keyboards, and so many others. Injection molding is ideal is for high volume production runs. With the right setup and tooling, several components can be produced in a single cycle with high tolerances, low labor costs, and minimal parts finishing. That being said, the single greatest drawback to injection molding is the initial upfront costs for creating custom molds and tooling. That is why getting the mold design right is so important.
Part designers can choose from literally thousands of different resins for an injection molding process. Most of these resins are thermoplastics, but some elastomers are also available. When deciding on which resin to use for a particular part, it’s important to weigh a resin’s flexibility, moldability, strength, and cost; these factors will also have an impact on the choice of mold material. The various metals that can go into a mold offer a variety of temperature handling capabilities and often respond in different ways to various processes. Consider how many parts you will need to manufacture and how often when creating a custom mold design. For example, molds cut from steel last longer and can typically handle more injection molding cycles than an aluminum one, but steel tends to be costlier. Does your project require the strongest materials or will less durable ones suit your needs? How many molds do you need to build at a time? How many do you need running at a time? How many do you need to reserve as backups?
Just as with resins, there’s a wide variety of injection molding machines to choose from - each with its own set of capabilities. They typically all have the same components: a material hopper, an injection ram or screw plunger, and a heating unit. Once molds are clamped to the machine and in the ready position, melted plastic is injected into the mold. Machines are rated by tonnage, which indicates how much clamping force the unit can exert. Machine tonnages typically range from 5 tons to 6,000 tons. Larger parts require higher tonnage machines to exert enough force to spread molten resin quickly through the mold cavity. To determine machine tonnage required, the projected area of the part is multiplied by a clamp force factor ranging from 2 to 8 tons per square inch of the projected area. As a general rule of thumb, a clamp force of 4 or 5 tons per square inch is sufficient for most products. Less flexible materials will require more pressure to fill the mold properly.
A mold, sometimes called a die or tool, represents a major portion of the costs associated with injection molding for most manufacturers because they often pay for designing and manufacturing their own molds, then loan them out to full-service contract manufacturers to carry out the actual injection molding process. Injection molds are usually cut from hardened steel, pre-hardened steel, aluminum, or a beryllium-copper alloy. The choice of material to use for your custom mold typically comes down to what makes the most sense financially. It is important to focus on the long-term cost versus up-front tooling cost. Hardened steel molds are more expensive to produce, but their wear-resistant characteristics allow for longer working lifespans and require less maintenance. Standard tool steels are less expensive, but they usually offer a shorter lifespan and require more maintenance.
Aluminum molds can be significantly less costly than steel molds and are usually intended for lower quantity production parts. Molds made of higher quality aluminum, such as QC-7 and QC-10, can produce hundreds of thousands of parts. Aluminum molds also have another advantage; they offer better heat dissipation properties than steel molds, so cycle times are shorter, allowing for quicker turnarounds. Aluminum molds can also be coated to help them withstand the heat and pressure longer, extending their useful life.
For parts that require higher temperatures than typical injection molded parts or fast heat removal, beryllium-copper molds are the best option.
A variety of molding methods are available for products or molds that demand specific techniques. To make more informed decisions, familiarize yourself with the different approaches to injection molding before finalizing your custom mold design.
Although “reduce your stress” sounds like an invitation to focus on your mantra, in the context of designing custom injection molds, stress reduction refers to a specific engineering technique. Injection molded parts can suffer from stress, which is due in large part to their design. When plastic resins are melted, this causes the bonds between their molecules to weaken and stretch temporarily. As the part cools, those bonds are reestablished and harden. When the plastic is forced through hard turns, various geometric features, and other sharp distortions, the material stretches further, creating a stress point, which is frozen into the part as the resin cools.
Stress in an injection molded part typically results in warpage, cracking, and premature failures, but other effects of part stress can also occur.
Here are some key approaches to minimizing part stress:
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[post_title] => Custom Mold Design: Part 1 [post_excerpt] => Have you considered ALL of the angles with your custom mold design? Is your injection molding manufacturer providing you all of the important details? [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => custom-mold-design-part-1 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-custom-mold-design-part-1/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [58] => WP_Post Object ( [ID] => 2379 [post_author] => 3 [post_date] => 2018-10-24 14:22:00 [post_date_gmt] => 2018-10-24 19:22:00 [post_content] =>
At Ferriot, we realize that many (if not most) savvy medical industry OEMs want to focus on their core competencies and let another company perform the details of the actual product build. Contract Manufacturing provides numerous opportunities to greatly reduce capital expenditures and operating costs while ensuring the highest quality for the final product.
What we’ve learned over our years of experience is that there’s a clear process to follow to guarantee success when using a contract manufacturer. When done correctly, applying the right process results in both great customer satisfaction and great performing products.
For companies considering transitions or moving production to a contract manufacturer, the process is very much the same as when entering any long-term business relationship. It's all about gathering as much information as possible and then making an educated, informed choice.
In the article, Seven Steps to Successful Contract Manufacturing for the Medical Industry, our very own Dave Hartman presents some guidelines that can be used as a road map for a successful partnership between a medical industry OEM and a contract manufacturer including these steps:
To learn more about all seven steps to contract manufacturing success, read the full article in Medical Design Briefs.
Ferriot is a full-service provider of injection molded products ranging from enclosures and encasements for medical equipment to business machines, industrial and consumer products. Our extensive expertise includes engineering, tooling design, injection molding, custom molding, sub- and finished assembly and the on-time delivery of components and finished products for major industry.
Ferriot’s engineering team can design complex molds and develop products with outer surfaces with a varying range of performance requirements necessary in a medical environment. The team takes products and components from concept to finished manufacturing — starting with mold design and engineered resin selection, to finished product production, complete with decorative finishes and branding.
Examples of our medical solutions include:
With almost 90 years of institutional experience, a trained workforce averaging nearly 20 years of experience per employee and a 200,000-square-foot facility, Ferriot runs multiple assembly lines around the clock. Quality-control extends to every product they turn out.
Contact Ferriot to learn more.
Learn more:
[post_title] => Medical Industry Contract Manufacturing Success featured in Medical Design Briefs [post_excerpt] => The seven steps to successful contract manufacturing in the medical device industry are featured in Medical Design Briefs. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => medical-industry-contract-manufacturing-success-featured-in-medical-design-briefs [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-medical-industry-contract-manufacturing-success-featured-in-medical-design-briefs/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [59] => WP_Post Object ( [ID] => 2381 [post_author] => 3 [post_date] => 2018-09-24 16:28:00 [post_date_gmt] => 2018-09-24 21:28:00 [post_content] =>
We're pleased to announce that Craig Ferriot, President, Ferriot, Inc. will be speaking at the MFG DAY event on October 5th at the Hilton Garden Inn, Akron, OH. Craig's presentation will highlight some of the technological innovations being utilized in the injection molding industry.
"Celebrate Manufacturing Day: Spotlighting Innovation in Northeast Ohio”
Join us for breakfast as we highlight how manufacturers in northeast Ohio are using innovative technology. Dress is business casual.
Manufacturing Day®, a celebration of modern manufacturing, occurs annually on the first Friday in October. Using the theme “Open Doors, Open Minds” the event is meant to inspire the next generation of manufacturers.
For more information on the MFG DAY Event and to register to attend, click here.
[post_title] => Craig Ferriot to speak at MFG Day Event [post_excerpt] => Craig Ferriot, President, Ferriot, Inc. will be speaking at the MFG DAY event on October 5th at the Hilton Garden Inn, Akron, OH. Craig's presentation will highlight some of the technological innovations being utilized in the injection molding industry. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => craig-ferriot-to-speak-at-mfg-day-event [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-craig-ferriot-to-speak-at-mfg-day-event/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [60] => WP_Post Object ( [ID] => 2383 [post_author] => 3 [post_date] => 2018-07-11 12:33:00 [post_date_gmt] => 2018-07-11 17:33:00 [post_content] =>
It’s not every day that your company gets featured in a trade publication! It’s even more unique to be worthy of the cover story! The Ferriot team is proud to share with you our BIG IDEAS as they come to fruition.
Throughout the history of manufacturing it seems that consumer needs often result in innovation, one way or the other.
Here at Ferriot, we’ve been seeing an uptake in demand for adding additional molded-in features to plastic parts—especially larger, injection molded structural foam parts. This is also a much more cost-effective solution for assembly.
Recently, we added a 2,250-ton Negri Bossi Bi-Power, our largest press ever! It took a fleet of five 18-wheelers to deliver. The entire system encompasses a Conair Carousel Plus W400 dehumidifying dryer, a Kuka six-axis robot and a conveyor. We had to take a novel approach by integrating the Sytrama SCP2 control with the Kuka. Our aim in all this was to make programming the robot easier for the technicians.
Clients demand parts that are precise, and with Ferriot’s 20 injection molding presses we are committed to finding them a solution that works. The key with injection molding is how quickly the machine can be changed over from part to part. Downtime costs money and we don’t want to pass those costs on to our clients.
We recently talked about this with Plastics Machinery. You can download the full article here.
Learn more:
[post_title] => Ferriot featured in Plastics Machinery Magazine! [post_excerpt] => At Ferriot, we’ve been seeing an uptake in demand for adding additional molded-in features to plastic parts—especially larger, injection molded structural foam parts. This is also a much more cost-effective solution for assembly. Here's our BIG IDEA... [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => ferriot-featured-in-plastics-machinery-magazine [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:14 [post_modified_gmt] => 2024-03-11 20:11:14 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-ferriot-featured-in-plastics-machinery-magazine/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [61] => WP_Post Object ( [ID] => 2385 [post_author] => 3 [post_date] => 2018-05-02 17:48:00 [post_date_gmt] => 2018-05-02 22:48:00 [post_content] =>
Design engineers and their employers have shifted focus from the days when their company created an injection-molded part, turned it over to a contract manufacturer, and the purchasing department followed-up on delivery.
For production quality, cost control and innovative solutions, design engineers and their companies now seek vendor-as-partner relationships. The exchange of knowledge between designer/company and vendor creates an inclusive goal set, including part design/optimization, tooling modifications or simplifications, cost containment, just-in-time delivery and special finishes. The result is a vendor who can “fill the gaps” in the company’s capabilities to identify positive, proactive opportunities beyond the customer’s RFQ.
One customer shifted their focus when they needed help in creating parts for a redesign of one of the company’s top sellers.
“We look for vendors with experience in areas of injection molding we need.” The material manager found a vendor that had molded faceplates for ATMs and gasoline pumps which would withstand extreme conditions like temperature changes and chemical exposures. The material manager explained “These products the vendor created were rugged, and even after exposure to the elements, the finish still looked great. Our product would never be in those conditions, but they had the experience to develop quality and durable products for those industries. They certainly have the technology to develop products for us.”
Qualifying multiple vendors for key injection molding is standard. The first reason for having a contingency plan is obvious: preparing in the event of unexpected major equipment failure, fire, work stoppage or other disaster.
A second qualifying practice makes good economic sense. This customer screens alternative suppliers for comparative price checks. Customer finds “Price protection is a thing of the past; every price is subject to change based on every little market whim. Without market index pricing with a particular vendor, I need to confirm pricing, and I do that with a second vendor source. If one vendor claims a price increase, I want to see that market adjustment with all my sources.” The customer is reasonably wary about price increases, “Sometimes, frequent price increases may indicate a vendor’s processes are faulty, creating too much scrap, for example.”
For this customer, they were able to identify their critical characteristics for an injection molding partner:
Keep reading this case study that shows the company’s selection process in finding that responsive, reliable and innovative vendor partner. Download the entire study, to learn more about the targeted questions they asked of vendors, and how they found and developed the vendor-as-partner relationship to support their direct injection-molding needs. Find best practices in evaluating direct injection molding vendors you can apply today.
[post_title] => Case Study: How to turn an Injection Molding Vendor into a Partner [post_excerpt] => Learn how to turn an Injection Molding Vendor into a full-service Contract Manufacturing Partner from industry experts at Ferriot. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => how-to-turn-an-injection-molding-vendor-into-a-partner [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:15 [post_modified_gmt] => 2024-03-11 20:11:15 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-how-to-turn-an-injection-molding-vendor-into-a-partner/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [62] => WP_Post Object ( [ID] => 2387 [post_author] => 3 [post_date] => 2018-04-17 14:20:00 [post_date_gmt] => 2018-04-17 19:20:00 [post_content] =>
Akron, Ohio, April 17, 2018: Ferriot Inc., a custom injection molding company and contract manufacturer has appointed two new members to its quality team. Richard Hodnick has been appointed to Director of Quality and Joe Steger as Quality Engineer.
Rich has 30 years of experience leading both public and private companies in the areas of quality assurance, process engineering, reliability engineering and project management. Rich and his team of quality improvement engineers and technicians will be charged with advancing both our capabilities and increasing responsiveness and satisfaction levels with our customers.
Rich’s initial goals are registration of Quality Management Systems (QMS) for Ferriot and wholly owned subsidiary, American Original Building Products LLC, to the new ISO 9001:2015 quality standards. In addition, he will focus on fully integrating the QMS into the IQMS ERP system allowing the company to fully realize the benefits of this closed loop business system.
Quality Engineer, Joe Steger, has served in several significant quality and manufacturing roles that include 13 years as Quality Assurance & Reliability Lead Engineer and 10-years of experience as a CNC machinist and molding/tooling/finished good inspector. Recent accomplishments for Joe include co-developing and implementing a reliability testing laboratory. He looks forward to getting know Ferriot’s valued customers and becoming familiar with IQMS.
Craig Ferriot, President of Ferriot, Inc. said, “Both are great additions to our team and understand the importance of customer satisfaction.”
Ferriot, Inc. is a full-service contract manufacturer and custom injection molder of engineered resins. Privately held since its founding in 1929, Ferriot employs veteran engineers and skilled technicians of the manufacturing and plastic injection molding industry. Ferriot’s contract manufacturing services include engineering, design, molding, sub- and final assembly, delivery of components and finished products for a variety of industries. Markets include building and construction, medical, industrial, business machines, oil and gas, electronics, consumer goods and more.
[post_title] => Growing Injection Molder/Contract Manufacturer Focuses on Quality for Long-Term Success [post_excerpt] => Richard Hodnick has been appointed to Director of Quality and Joe Steger as Quality Engineer. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => growing-injection-molder-contract-manufacturer-focuses-on-quality-for-long-term-success [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:15 [post_modified_gmt] => 2024-03-11 20:11:15 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-growing-injection-molder-contract-manufacturer-focuses-on-quality-for-long-term-success/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [63] => WP_Post Object ( [ID] => 2390 [post_author] => 3 [post_date] => 2018-04-12 14:15:00 [post_date_gmt] => 2018-04-12 19:15:00 [post_content] =>Structural foam molding has become a highly evolved technique. Today, thermoplastic resin can be mixed with a chemical blowing agent to expand the melted resin and produce high-strength parts for use in industrial applications. The thermoplastic microcellular structure weighs 10% to 30% less and is stronger and more resilient than traditional injection molded parts.
The Brave New World of Structural Foam Molding
Modern structural foam molding vs injection molding differs significantly. “Structural foam” describes the result of the blend of thermoplastic resin and blowing agent when activated by heat. The blowing agent creates a foamed microcellular structure that fits itself into the form of the mold.
Structural foam molding can be conducted at lower pressures than injection molding creating less stress on the formed parts and therefore, less warping. This low-pressure technique also allows for the use of much less expensive tools. Long-lasting molds can be made of aluminum rather than tool steel. Structural foam molded parts are stronger and lighter than parts created with traditional injection molding techniques because they aren’t as dense.
Structural Foam Parts Are Lighter and Stronger
Structural foam parts have much higher strength-to-weight and strength-to-stiffness ratios than injection molded parts. They are also much more impact resistant due to the microcellular structure.
When parts need to be scaled up in size, structural foam molding is the optimal strategy. Structural foam molding can be used to create small parts or much larger, complex parts without sacrificing the speed that would be required to injection mold larger parts.
As an additional benefit, structural foam molded parts have zero sink marks. Sink marks resulting from injection molding and can leave a rough, unsightly surface that is difficult to clean. Structural foam molding leaves a smooth external surface that is easily cleaned and can even be painted if desired.
Ferriot: Structural Foam Molding Specialists, and Just Good People
Ferriot has developed an in-depth understanding of the vast new set of strategies behind structural foam molding processes. Ferriot now operates a high-quality in-plant structural foam molding system. Many Ferriot customers are so confident in the quality of Ferriot’s foam molded parts that they are shipped directly to end users.
As an additional benefit, Ferriot is a quality-oriented, engineering-oriented organization that strives to do things right the first time. They understand that product quality and delivery, and vendor reliability are crucial in today’s markets.
Among Ferriot’s customers, many deeply appreciate the company’s willingness to handle short runs with high levels of process automation. Ferriot’s superior shop-floor documentation and process control often attract new customers and keep existing customers coming back.
One such customer is ILC Dover. You can read the full case study here.
[post_title] => Foam Molding Produces Lighter, Stronger Parts at Lower Cost [post_excerpt] => Ferriot has developed an in-depth understanding of the vast new set of strategies behind structural foam molding processes. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => structural-foam-molding-process-produces-lighter-stronger-parts-at-lower-cost [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:15 [post_modified_gmt] => 2024-03-11 20:11:15 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-structural-foam-molding-process-produces-lighter-stronger-parts-at-lower-cost/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [64] => WP_Post Object ( [ID] => 2392 [post_author] => 3 [post_date] => 2018-03-28 17:16:00 [post_date_gmt] => 2018-03-28 22:16:00 [post_content] =>Many medical device original equipment manufacturers (OEMs) work with a contract manufacturer on the fabrication and assembly of products for new product designs, especially when the parts need to be precisely machined or cast. In the case of parts made from engineered resins, it is essential that OEMs of medical devices find contract manufacturers (CMs) that do excellent, precise work the first time, every time.
Meeting of the MindsWhile a part may be conceived and designed, it is still important for the OEM to choose a CM that has extensive experience manufacturing medical devices and is a good fit culturally. The CM must have the knowledge, equipment and resources to produce medical components with the accuracy and in the numbers that the OEM requires. For the two companies to share a corporate culture and an overall approach to work can also be beneficial in terms of the ensuing business relationship.
The collaborative process is much easier if the manufacture of an existing product is being transferred, all work instructions and current sources should be shared with the new CM. If a new component is being manufactured or a new product being launched, the CM may well be responsible for developing the assembly flow and the work instructions for the build.
Starting from Scratch
In an alternative scenario, if sources for components must be identified and inspected, a different sort activity begins. The entire development, qualification, and supply line management for components must be developed. Ferriot specializes in this type of relationship. This requires an experienced team who are familiar with the medical industries, with the processes and standards particular to medical injection molding, such as cleanliness standards, lot number traceability, medical drying procedures and superior tight tolerance precision molding.
Design Accuracy
When an OEM is working with a CM, there are a number of steps that can be taken to ensure that a medical device or medical device component is produced precisely and exactly as required on the first run and on every subsequent run. The accuracy of the process begins at the beginning; It starts with a clearly defined product.
The design and specification of any medical-related products must be performed in a very accurate and precise manner. The use of computer aided design (CAD) for medical devices or components is essential in the early stages. The plans created using CAD programs are themselves very detailed and accurate and this can help in the production of accurate components.
Production
Once the flow, work instructions, and components are all in place, operator training and qualification starts. Pilot builds are conducted and comprehensive qualification of the finished product or sub-assembly is the last major effort in preparation for production. This should be carried out by the medical inventor of the product and/or a medical professional with knowledge of medical device production.
As the production phase is entered, having a good plan drives procurement, production and inventory. Having a realistic forecast upon which to build the production plan is very important. When it’s done well, the process will provide great customer satisfaction and great final product.
A Good Contract Manufacturer
There are numerous aspects to manage, when an OEM is participating in a new production program. A good CM will allow the OEM to remain focused on their core competency and intellectual property.
When the CM is truly serving the needs of an OEM, the OEM can spend less capital, hire fewer laborers, spend less time on quality control, worry less about purchasing and know that someone else is ensuring the technical skills of the people involved. The OEM can also control inventories at manageable levels, without being required to focus on details.
Perhaps most important, working with a quality CM offers a single point of contact for everything an OEM might need. There is no more worrying about whether all of the production partners will be able to supply the required components. A good CM takes care of these concerns well in advance.
At Ferriot, we know that manufacturing is complex, but we don’t think it should be more complicated for you than it needs to be. We think of contract manufacturing as a partnership. Like any good partnership, that means we work hard to ensure you get what you need at high quality, on time and on budget.
Learn more about the 7 Steps to Successful Contract Manufacturing for the Medical Industry.
[post_title] => Steps to Building an Optimal Relationship between a Medical Device OEM and a Contract Manufacturer [post_excerpt] => Many medical device original equipment manufacturers (OEMs) work with a contract manufacturer on the fabrication and assembly of products for new product designs, especially when the parts need to be precisely machined or cast. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => steps-to-building-an-optimal-relationship-between-a-medical-device-oem-and-a-contract-manufacturer [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:15 [post_modified_gmt] => 2024-03-11 20:11:15 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-steps-to-building-an-optimal-relationship-between-a-medical-device-oem-and-a-contract-manufacturer/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [65] => WP_Post Object ( [ID] => 2395 [post_author] => 3 [post_date] => 2018-03-12 14:11:00 [post_date_gmt] => 2018-03-12 19:11:00 [post_content] =>Manufacturing plant engineering Green Energy with new air-cooled compressor
Akron, Ohio – March 12, 2018 – Ferriot, Incorporated, an injection molding and contract manufacturing company, is installing a new heat recovery system to improve the facility’s energy efficiency and lower operating costs.
Ferriot operates a 200,000-square foot facility in Akron, Ohio. Running the machinery and heating a facility of that size requires a lot of energy. To conserve energy while growing the business, Ferriot’s new heat recovery system will re-use waste heat for space heating. The term “heat recovery” describes the collection and re-use of heat arising from any process that would otherwise be lost.
For many businesses, including Ferriot, heating and cooling is one of the more significant operating costs. A typical office building in the northern U.S. can spend nearly 40 percent of its energy cost on heating. Most businesses use another six percent of its energy usage on heating water. For many industries, especially manufacturing, heating demands are even higher. Steam and process heating can account for more energy use than space heating.
In Ferriot’s case, waste heat recovery will come from the air compressor that powers all of its machines. The company will be moving from a water-cooled compressor to an air-cooled compressor when it installs a new 125 HP Sullair Air Compressor. The Sullair compressor has a variable frequency drive, allowing it to only run when needed. It will also reduce the load on the water tower by cooling with air instead of water.
“This new air-cooled compressor system will allow Ferriot to realize an energy savings between 10 and 15 percent,” said company President Craig Ferriot. “The greatest energy savings will be realized in cooler months. More than 90 percent of energy input to a compressor is lost as heat when the air is extracted and dumped into the environment. Reducing energy consumption occurs when this heat is captured for use elsewhere.”
The Sullair Air Compressor heat exchanger will be connected to ductwork. The warm air generated by running the compressor will be blown back into the plant to heat the space – a process that is becoming more common in manufacturing. The heat energy is passed into the production space. This will enable Ferriot to shut down two air handling units that provide comfort heat in certain areas of the plant. A more powerful air compressor and less draw on water for cooling purposes, will also provide additional capacity for cooling the new presses and other equipment.
This state of the art compressor has other benefits including a 10-inch screen display with a computer and mobile phone connection allowing for remote monitoring.
About Ferriot Inc.
Based in Akron, Ohio, Ferriot is a full-service contract manufacturer and molder of engineered resins that provides specialized engineering assistance, complex thermoplastic material development, injection molding, painting and decorating, contract manufacturing, and commitment to total quality management. Ferriot provides these services throughout the United States to customers in the following markets/applications: Business Machines, Building Products, Industrial, Medical Devices, Electronics, Bio-Tech, Energy Management, Oil and Gas, Water Management and Tier 2 Automotive. To learn more, visit www.ferriot.com.
[post_title] => 10 Critical Questions to Ask Before Starting an Injection Molded Project
[post_excerpt] => We’ve narrowed it down to 10 critical questions you should ask before beginning any injection molding project.
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[post_content] => As we mentioned in our blog last week, Ferriot is in the process of installing a new 2,250-ton Negri Bossi Bi-Power injection molding press. We were very excited to see this announcement featured in Plastic News and are both thrilled and a little humbled by the mention.
Ferriot is investing more than $1 million in the new press that will enable us to increase our production capabilities and address the on-time delivery needs of our growing customer base. The full installation will also be documented via Go Pro and the installation progress will be shared on our website.
Craig Ferriot, our company President said, “one of Ferriot’s niches is large, high-pressure structural foam medical and business machine housing that require high cosmetic finishes, which is one of the target markets for this press.”
Ferriot Inc. is honored to be mentioned in Plastic News. We’re excited for all to watch the progress of this installation. This is our first time documenting an installation for all to see.
You can read the full article from Plastic News by clicking here, Ferriot putting more than $1 million into equipment, infrastructure.
To read our blog detailing the progress updates click here, Progress Updates on New Negri Bossi BI‑POWER Injection Molding Press Installation
To continue to follow up on the latest press installments, subscribe to our email list.
[post_title] => Plastic News Features Ferriot’s Latest Injection Molding Press Install [post_excerpt] => As we mentioned in our blog last week, Ferriot’s latest installing of a new 2,250-ton Negri Bossi Bi-Power injection molding press. We were very excited to see this announcement featured in Plastic News and are both thrilled and a little humbled by the mention. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => plastic-news-features-ferriots-latest-injection-molding-press-install [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-plastic-news-features-ferriots-latest-injection-molding-press-install/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [68] => WP_Post Object ( [ID] => 2402 [post_author] => 3 [post_date] => 2018-01-25 15:06:00 [post_date_gmt] => 2018-01-25 20:06:00 [post_content] =>
Once installed, the Negri Bossi injection molding press, six-axis robot and auxiliary equipment will take up a 25-by-60-foot area on the shop floor. The company is providing updates on the installation via a GoPro camera.
Ferriot Inc. is investing more than $1 million in a project that includes the installation of a new 2,250-ton Negri Bossi Bi-Power injection molding press, six-axis robot, auxiliary equipment and infrastructure improvements.
Craig Ferriot, president of the Akron, Ohio-based custom injection molder and contract manufacturer, said business is increasing, especially for larger parts, including cosmetic enclosures for markets such as business machines, electronics, medical devices, industrial components and consumer products.
"One of Ferriot's niches is large, high-pressure structural foam medical and business machine housings that require high cosmetic finishes, which is one of the target markets for this press," he said in an email interview.
The new press will come equipped with a wireless Amico system for remote monitoring in addition to an IQMS ERP system that Ferriot installed and implemented across all of its presses in 2015. Press connectivity and industry 4.0 upgrades enable better reporting to improve processes and efficiencies, Ferriot said.
"IQMS connects our machines to our enterprise system, allowing process monitoring in real time," he added. "This gives visibility of production status and traceability to customer orders."
The 2,250-ton Negri Bossi will be Ferriot's largest machine yet — presses at the company start at clamping forces of 42 tons — and the company's first time documenting the installation for all to see.
To do so, Ferriot has installed a GoPro camera on the ceiling of the production area where the new press will be assembled. Each week, the company will provide photo updates online and will eventually release a time-lapse video of the full installation.
"By using time-lapse photography, we want to show what it takes to install a piece of equipment like this and, in the end, will produce a video that shows the process from start to finish," Ferriot said.
So far, the concrete foundation has been poured and cured, and the infrastructure has been put in place. Arrival of the press and auxiliary equipment, which will be delivered on five semitruck loads, was delayed three weeks due to weather at the port and a standstill at U.S. Customs and Border Protection. Ferriot expects the first truck to reach the facility the week of Jan. 29.
The press should be fully operational and producing the first orders for customers by mid March, he added.
"We intend to continue investing in technology and retire old assets," Ferriot said in a follow-up phone interview. "We're seeing most of the opportunities right now in machinery that is 500 tons and up."
With the addition of the new Negri Bossi press, Ferriot will have 20 injection molding machines at its 200,000-square-foot facility. The company has roughly 130 employees after increasing its workforce by about 15 percent over the last year, Ferriot said.
Ferriot ranks No. 186 in the annual survey of injection molders by Plastics News, with estimated sales of $30 million.
[post_title] => Ferriot Putting More Than $1 Million Into Equipment, Infrastructure [post_excerpt] => Ferriot Inc. is investing in a new 2,250-ton Negri Bossi Bi-Power injection molding press, six-axis robot, auxiliary equipment and infrastructure improvements. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => ferriot-putting-more-than-1-million-into-equipment-infrastructure [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-ferriot-putting-more-than-1-million-into-equipment-infrastructure/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [69] => WP_Post Object ( [ID] => 2404 [post_author] => 3 [post_date] => 2018-01-24 19:39:00 [post_date_gmt] => 2018-01-25 00:39:00 [post_content] =>As anyone who’s worked in construction can tell you, nothing draws a crowd of “sidewalk superintendents” quite like the sight of someone else hard at work. Now, you can join the crowd without ever leaving your desk. Ferriot has installed a Go Pro camera on the ceiling in the production area, above the area where we’re assembling our new 2,250-ton Negri Bossi BI‑POWER injection molding press. Each week, Ferriot will update the photographs to allow checking in on the progress of the installation. In addition to using these photographs for sales and marketing purposes, the camera will let us document this milestone in our company history with a time-lapse video. To check on project status, visit our Negri Bossi Press Installation Progress page.
I’m happy to report the installation is proceeding on schedule (more or less), with the site preparation and floor reinforcement phases now complete. The concrete foundation we poured at the end of November has cured and the massive components of the press (one of which weighs 70 tons!) and its peripherals will be delivered on five semi-truck loads. Due to an unusually cold winter, the components must be inside our building for a few days and must reach room temperature before installation can begin. Installation should be completed by late February.
The press configuration we chose is designed to support producing the largest plastic parts we’ve ever handled. Once it’s installed, the press will allow us to boost production capacity, operate more efficiently, and reduce delivery times to our customers. The installation of the press is part of our long-term plant reconfiguration effort designed to use floor space more efficiently, boost labor productivity, simplify movement and the flow of work through the facility, and ease supervision.
The new press will have an integrated Columbia industrial PC and a variable delivery pump hydraulic system that allows for precise process control and high power efficiency. The support team at Negri Bossi will be able to monitor its operation remotely via the Internet at any time so they can perform diagnostics, troubleshooting, and intervention in real time.
We invite you to stop by the Negri Bossi press installation page to check out our progress. You can also follow us on LinkedIn, Facebook and Twitter.
If you want an overview of how a press of this type comes together, why not take a few minutes to watch a YouTube video that shows one of Negri Bossi’s larger Bi-Power presses being assembled? It’s available at https://youtu.be/bEmbwcb3oWs.
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[post_title] => Progress Updates on New Negri Bossi BI‑POWER Injection Molding Press Installation [post_excerpt] => Ferriot has installed a Go Pro camera on the ceiling in the production area, above the area where we’re assembling our new 2,250-ton Negri Bossi BI POWER injection molding press. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => progress-updates-on-new-negri-bossi-bi-power-injection-molding-press-installation [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-progress-updates-on-new-negri-bossi-bi-power-injection-molding-press-installation/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [70] => WP_Post Object ( [ID] => 2413 [post_author] => 3 [post_date] => 2017-12-19 15:02:00 [post_date_gmt] => 2017-12-19 20:02:00 [post_content] =>New press to increase production capacity, speed customer service significantly
Akron, Ohio – December 19, 2017 – Buyers of oversized injection molded plastic parts will have another potential supplier in 2018. The site preparation and floor reinforcement process for a new 2,250-ton Negri Bossi BI-POWER injection molding press has already begun at the Ferriot, Incorporated production facility on Arlington Circle in Akron, Ohio. The press, which will be installed after the New Year, will be the largest in Ferriot’s core business “fleet.”
Company President Craig Ferriot noted, “We invested in the 2,250-ton press to increase our production capacity, operate more efficiently, and accelerate our delivery times for finished products. This new press will also serve as a back-up to our next-largest press, so our customers for larger plastic parts can be confident we’ll always have the capacity to turn around their orders quickly.”
He continued, “Assembling the press and all its peripheral devices—robots, dryers, conveyors and magnetic platens—will involve plenty of steps. To document this process and allow our employees and interested customers to follow along, we’ll be installing a camera that will take periodic time-lapse photographs of the assembly process.”
The Negri Bossi BI-POWER VH2000-22500 press features an integrated Columbia industrial PC and a variable delivery pump hydraulic system designed to deliver precise process control and high power efficiency. A wireless Amico™ system will enable remote monitoring of the press around the clock, which will allow the press’s manufacturer to perform remote diagnostics, troubleshooting, and intervention in real time via the Internet, ensuring greater uptime performance. Ferriot’s press will be paired with a new KUKA multi-function robot and IQMS enterprise systems to provide numerous automation capabilities.
The installation of the press is part of Ferriot’s long-term plant reconfiguration effort designed to use floor space more efficiently, boost labor productivity, simplify movement and the flow of work through the facility, and ease supervision.
Follow the installation progress here.
About Ferriot Inc.
Based in Akron, Ohio, Ferriot is a full-service contract manufacturer and molder of engineered resins that provides specialized engineering assistance, complex thermoplastic material development, injection molding, painting and decorating, contract manufacturing, and commitment to total quality management. Ferriot provides these services throughout the United States to customers in the following markets/applications: Business Machines, Building Products, Industrial, Medical Devices, Electronics, Bio-Tech, Energy Management, Oil and Gas, Water Management and Tier 2 Automotive. To learn more, visit www.ferriot.com.
Akron, OH – October 12, 2017: The engineering website MachineDesign recently featured an article cowritten by Ferriot’s Dave Perkowski and Dave Swigeart, “The Design Engineer’s Checklist for Injection Molding.” Based on Ferriot’s decades of experience as an injection molder, it highlights the importance of resin selection, process choices and design specs when designing and executing any injection molding project.
As any seasoned engineer knows, the design stage is crucial for ensuring that the part will achieve its full potential in its intended application, and careful planning helps to eliminate cost and time overruns during the process.
The article outlines the steps that any design engineer should take before diving into their injection molding project. For example, the first step in designing any injection molded part is answering some basic questions:
The checklist features other considerations that should be shared between the engineer/designer and injection molder and is available for free here. For more information on Ferriot and its injection molding and other contract manufacturing services, visit www.ferriot.com.
Ferriot Inc. is a full-service contract manufacturer and injection molder of engineered resins. Privately held since its founding in 1929, Ferriot employs veteran engineers and skilled technicians of the manufacturing and plastic injection molding industry. Ferriot’s contract manufacturing services include engineering, design, molding, sub- and finished assembly and delivery of components and finished products for a variety of industries including building and construction, medical, industrial, business machines, oil and gas, electronics and more.
[post_title] => MachineDesign Publishes Ferriot’s Molding Checklist For Design Engineers [post_excerpt] => The article outlines the steps that any design engineer should take before diving into their injection molding project. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => machinedesign-publishes-ferriots-molding-checklist-for-design-engineers [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-machinedesign-publishes-ferriots-molding-checklist-for-design-engineers/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [72] => WP_Post Object ( [ID] => 2415 [post_author] => 3 [post_date] => 2017-10-09 20:13:00 [post_date_gmt] => 2017-10-10 01:13:00 [post_content] =>The recognized industry journal Machine Design just profiled Ferriot’s injection molding checklist in a recent article published on its website.
Design engineers know that planning is the most important step when it comes to any process, and injection molding is no exception. Working with an injection molder gives you the advantage of being able to focus on key design decisions rather than the in and outs of the molding process. Before diving in to the production stage, though, there are key considerations that you and your injection molder should agree on to avoid cost and time overruns.
A great first step is clearly defining project overview considerations. You should be aligned on key questions such as:
Making sure you and your injection molder are on the same page in terms of project goals and priorities ensures a smoother process from start to finish, eliminating costly changes midstream or even after production.
Next, you’ll want to agree upon the molding technologies to suit your application. From traditional injection molding to gas-assisted injection molding, each method has its own benefits unique to the application. Clearly outlining the objectives will help make the selection of the technology much easier and effective in the long run.
From material selection, to overall cost, to the product’s intended lifecycle, there are a host of considerations that should be on your injection molding checklist before you start the production process. To learn how to best tackle injection molded parts development, read our entire checklist and more in our Design Engineering Injection Molding Handbook.
[post_title] => The Design Engineer’s Checklist for Injection Molding [post_excerpt] => Tips and tricks for design engineers before choosing an injection molder. Learn about key design considerations to avoid cost and time overruns. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => the-design-engineers-checklist-for-injection-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:16 [post_modified_gmt] => 2024-03-11 20:11:16 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-the-design-engineers-checklist-for-injection-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [73] => WP_Post Object ( [ID] => 2417 [post_author] => 3 [post_date] => 2017-08-15 18:22:00 [post_date_gmt] => 2017-08-15 23:22:00 [post_content] =>We were pleased to participate in the Industrial Design & Engineering show this past May in Cleveland, Ohio. This show brought together design engineers and plant managers from across the country to learn about emerging technologies and to share their experiences.
Ferriot’s Dave Harman describes a successful Metal-to-Plastic Case History example to show attendees at the Industrial Design & Engineering Show. Picture Courtesy of Machine Design.
During this year’s show, Ferriot was one of five companies participating in the Case Study Corner, where each firm shared details on how they helped a customer. We chose to refer to recent project that involved helping a customer switch from metal to plastic components in their product. It was a very successful strategy for both Ferriot and our customer that not only helped them reduce costs, but also increased the longevity of their components with a more durable plastic part. This particular customer produces the gas station pump housings we all see. Since this part is visible to the consumer, it had to perform well, be cost-efficient to manufacture, and look great to the consumer as well. Ferriot used a lot of our resin selection expertise to recommend a resin that would be chemical resistant, support a high gloss consumer polish and not crack in either hot or cold temperatures.
We’d like to thank Machine Design magazine, one of the show sponsors, for writing about our participation in its blog article. I’d encourage you to read the article to learn about the other four companies that participated in the Case Study Corner, and read our Case History to learn more about the application.
Perhaps, But It’s Worth a Look To Get the Structural Integrity of Metal or Wood, with Lower Weight and Production Costs
If you’re considering a switch to plastic from metal, wood, concrete, fiberglass or other traditional material, structural foam injection molding may be just the process for you.
Structural foam molding is an injection molding process whose injection stage is basically the same as traditional injection molding, but the packing stage is augmented by a chemical blowing agent mixed with the thermoplastic material to create thermoplastic foam. That chemical blowing agent is triggered by heat and expands the material by creating a microcellular structure to form the part against the mold.
The advantages of converting to structural foam injection molded plastics are just as varied as the many products that can be made successfully by this process. They include higher stiffness-to-weight ratios (parts made with structural foam molding can weigh 10 to 30 percent less than other parts, while retaining durability), lower material costs, lower tooling costs, smoother finished part surfaces for easy painting and cleaning, and a wide range of design flexibility.
Some common – and uncommon – products that have been successfully converted from traditional materials to structural foam injection molded parts include palettes for industrial and consumer use, a variety of lawn and garden equipment and supplies, car and truck door handles, sump pump tanks, surgical equipment and even more recently things like voting machine housing, screws and bolts, and even some concept vehicles.
Switching to structural foam injection molding can save costs at many steps along the way to your finished part. For example:
If you’re thinking about converting to a lower weight yet high-strength part to save on production time and costs, structural foam molding may just be the right design choice. When you’ve made the decision to switch, it’s important to share as much detail as possible about your project with your injection molding contractor up front.
Some questions that you and your injection molding partner can answer together include:
At Ferriot we actually recommend developing a project checklist that is shared between the designer, OEM and injection molding partner and referenced often to ensure understanding on the part of all stakeholders. In the end, all involved will appreciate the detail and heavy lifting up-front.
To read more about how to optimize your structural foam and other injection molded parts development process, download our free guideline, “Designing Injection Molded Parts: A Handbook for Designers & Engineers.” Or, if you prefer, call us at (330) 786-3000 for immediate attention.
Learn More:
[post_title] => Structural Foam Injection Molding: A Miracle Process? [post_excerpt] => If you’re considering a switch to plastic from metal or other traditional material, structural foam injection molding may be just the process for you. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => structural-foam-injection-molding-a-miracle-process [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:17 [post_modified_gmt] => 2024-03-11 20:11:17 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-structural-foam-injection-molding-a-miracle-process/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [75] => WP_Post Object ( [ID] => 2423 [post_author] => 3 [post_date] => 2017-05-30 14:00:00 [post_date_gmt] => 2017-05-30 19:00:00 [post_content] =>
How selecting the right design specs, resin and molding process can answer them
Injection molding is a highly-engineered process, and demand for it only continues to grow as more manufacturers replace traditional materials like wood, steel and fiberglass with thermoplastic resins that are lighter in weight but just as durable. Applications and uses for injection molded parts are numerous and expanding, with increased use in the medical, automotive, industrial, housewares, electronics industries, to name a few.
If you’re thinking about a conversion to resin injection molding, you may have questions about the quality of the finished part, what specs to design to, or what process is right for your application. Here are three common questions to ask that can help put your project on the right track from the beginning.
What specs do I design toward?
For most of our projects, they come down to understanding impact resistance on your part, heat exposure and color.
Impact Resistance
At Ferriot, once we know why impact resistance is important and the type of expected impact load (e.g., a fall onto a hard surface from 5 feet, or having loads dropped on it, etc.), our “upfront” impact testing offers valuable insights. By using molds that are similar to the final part, we can produce prototype parts using an array of resins, and then compare their impact resistance. We also conduct Notched Izod tests to measure impact performance expressed in energy lost per unit of thickness at the notch, based on ASTM D256 standards.
Heat Exposure
Your injection molding partner should also pre-test to determine the Heat Deflection Temperature (HDT), the temperature at which a plastic sample deforms under a specified load. The tests should reveal the maximum temperature the part can withstand without deformation.
Other heat exposure-related issues to consider for your part include knowing the type of heat source the part would be exposed to, i.e. a flame, sun exposure or heating element. You and your injection molder can also avoid heat exposure issues by knowing whether the part will be subject to interference with other materials. For example, dissimilar materials have considerable thermal expansions or contractions and may cause an interference condition.
Color Accuracy
The good thing about injection molded thermoplastic parts is the ability to ensure consistent color throughout the part with the right pigment to resin ratio. The problem can arise when trying to match a prescribed color standard. Even with the standard met, you could face the issue of color retention through UV, light and thermal exposure.
At Ferriot, we will test a number of pigment-resin formulas to make sure the resulting color matches your brand identity guidelines.
What resin is the right choice for my application?
Speaking of resins…the right choice of thermoplastic resin can alleviate many issues associated with impact resistance, heat exposure and color accuracy of injection molded parts.
Thermoplastic resins come in two basic classes: engineering grade resins and commodity resins. Here are a few resin types that meet impact, heat and color requirements.
Engineering Grades
Commodities Grades
Process matters: Which injection molding technology can overcome common issues?
With a few exceptions, Ferriot can accommodate almost any thermoplastic resin and nearly any design specifications.
Depending on your part’s requirements, traditional injection molding, structural foam injection molding, gas-assisted injection molding or overmolding – all processes available at Ferriot – will suit a wide range of applications.
The answers to those three questions involve a lot of complexity that you’ll want to discuss more with your contract manufacturing partner. We’ve compiled some additional questions to ask, along with a variety of checklists, to help with your injection molding journey. To read more about how to optimize the injection molded parts development process, download our free guideline, “Designing Injection Molded Parts: A Handbook for Designers & Engineers.” Or, if you prefer, call us at (330) 786-3000 for immediate attention.
[post_title] => 3 Common Questions About Injection Molded Parts [post_excerpt] => Injection molding is a highly-engineered process, demand continues to grow as more manufacturers replace traditional materials with thermoplastic resins. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => questions-about-injection-molded-parts [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:17 [post_modified_gmt] => 2024-03-11 20:11:17 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-questions-about-injection-molded-parts/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [76] => WP_Post Object ( [ID] => 2425 [post_author] => 3 [post_date] => 2017-05-23 14:52:00 [post_date_gmt] => 2017-05-23 19:52:00 [post_content] =>
We get it: some people are just not “list” people. But when it comes to a successful injection molding project, getting down to as much detail as possible is the best way to ensure a project’s success.
Applications and uses for injection molded parts are numerous and growing, with increased demand from the medical, automotive, industrial, housewares, electronics and many more industries. As such, more product designers, engineers and Original Equipment Manufacturers (OEMs) are inquiring about switching some parts or entire products to injection molded plastics.
Before meeting with an injection molder to discuss a project, completing a checklist will answer many questions up front, and help the process run smoothly from start to finished product. It may seem basic, but at Ferriot we actually work with customers through a checklist to help accelerate communication and collaboration – and eliminate costly late-stage problems and changes that can happen without clear project scope up front.
Here are a few broad project categories for your Injection Molding checklist, and some key questions that fall under each.
Project Overview
Design Specifications
Physical Attributes and Appearance
Project Cost and Delivery
We Don’t Mind the Heavy Lifting Up Front
At Ferriot, we appreciate the thought and questions that go into an injection molding project. The more factors to consider, the better: that way all project stakeholders are clear on expectations. In short – don’t be afraid to make that list!
Of course, the above questions are a sampling of common issues and questions to arise in most injection molding projects. To read more items that should be on your checklist and learn how to optimize the injection molded parts development process, download our free guideline, “Designing Injection Molded Parts: A Handbook for Designers & Engineers.” Or, if you prefer, call us at (330) 786-3000 for immediate attention.
[post_title] => An Injection Molding Checklist Gets All Involved On the Same Page [post_excerpt] => An Injection Molding Checklist Gets All Involved On the Same Page [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => traps-when-selecting-molding-resin-0 [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:17 [post_modified_gmt] => 2024-03-11 20:11:17 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-traps-when-selecting-molding-resin-0/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [77] => WP_Post Object ( [ID] => 2427 [post_author] => 3 [post_date] => 2017-05-17 20:36:00 [post_date_gmt] => 2017-05-18 01:36:00 [post_content] =>
Resin selection can be a tricky business. On top of balancing cost, performance, function and moldability to figure out the right resin for the job, it’s necessary to think how the part will be cleaned and if it will touch food or be used in a sterile medical environment. It’s easy to get overwhelmed and fall into a few traps. We’re here to share our experience to help you to avoid them.
Trap 1: Not Sharing Finished Products Details Early Enough
Share more information with your contract manufacturer than you think is necessary and do it as soon as you form your partnership. What often happens is the process has already begun when designers mention casually that they are stressed out about their customer’s upcoming test procedure on the part. That designer might quickly find themselves going over budget and missing their deadline because the test wasn’t taken into consideration in the resin selection process and it’s back to the drawing board. Overcommunicate with your manufacturer. Having too much information doesn’t exist in this business. By sharing everything you know about the final product usage and testing requirements, you increase your chances of a successful production.
Trap 2: Rushing the Process
We understand. You don’t want your production line sitting idle. You’re excited about being able to see your vision come to fruition and hold the part in your hands. But if you let those considerations take precedence over taking the time to go through the resin selection process properly, you may find yourself with parts that get rejected or worst of all, an end-product recall. Take a breath. A few extra hours or days in upfront planning and communication will be worth it when your project is a success.
Trap 3: Not Pressing Pause When It’s Not Going Well
You’ve engaged a contract manufacturer. When you first started talking to them, they were quick to say they could do the job. They didn’t ask a lot of questions. They seemed hyper-focused on the part itself, not necessarily how it would be used, how it would be cleaned, or how it would be tested. At first, you may take this as a sign of confidence, but warning bells should be going off in your head. Step back and press pause. After all of the strategizing, planning, designing, meetings and everything else that went into your process thus far, you need to evaluate whether this is the right partner for you.
Now that you’ve learned three traps not to fall into, you’ll want to download our white paper that includes more details on these three traps, five tips to help ensure your project is a success, and a high-level attribute list of the features of the most common engineering grade resins and commodities grades. The white paper “The Tips, Tricks, And Traps of Injection Molding Resin Selection” also includes links to two of our most popular workbooks.
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There are ten key questions designers must have the answers to for a successful conversion from other materials to resin injection molding. Whether the design is for medical devices, business machines or for an industrial application, arm yourself today with this valuable infographic checklist.
Akron, Ohio, April 11, 2017: Demand for injection molded parts continues to grow as more manufacturers replace traditional materials like wood, steel and fiberglass with thermoplastic resins that are lighter in weight, but just as durable.
Designers and engineers in the medical, automotive, industrial, housewares, electronics and many more industries are increasingly asking whether a conversion to resin injection molding for certain parts and components make structural and financial sense.
To help designers and engineers get their first-time injection molding projects off on the right foot, Ferriot Inc. has produced the guideline, “Designing Injection Molded Parts: A Handbook for Designers & Engineers.” The booklet covers proper part design, resin selection and tips on how to select the right injection molder.
The guide offers readers an overview of injection molding processes and various applications and materials. Additional sections help readers determine whether a resin conversion and injection molding are right for their projects. When injection molding is the right decision, the guide recommends important questions to ask a potential contract manufacturing partner, and a project checklist to help both the designer and injection molding partner stay on the same page from start to finish.
Some key questions and project considerations suggested in the guide include:
Also included in the guide are a project checklist and spaces for notes and questions to be shared between the engineer/designer and injection molder.
The handbook is available online at no charge by visiting here. For more information on Ferriot and its injection molding and other contract manufacturing services, visit www.ferriot.com.
Ferriot Inc. is a full-service contract manufacturer and injection molder of engineered resins. Privately held since its founding in 1929, Ferriot employs veteran engineers and skilled technicians of the manufacturing and plastic injection molding industry. Ferriot’s contract manufacturing services include engineering, design, molding, sub- and finished assembly and delivery of components and finished products for a variety of industries including building and construction, medical, industrial, business machines, oil and gas, electronics and more.
[post_title] => New Injection Molding Handbook Tells Designers and Engineers Success Factors for Part Design and Resin Selection [post_excerpt] => The booklet covers proper part design, resin selection and tips on how to select the right injection molder. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => new-injection-molding-handbook-tells-designers-and-engineers-success-factors-for-part-design-and-resin-selection [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:18 [post_modified_gmt] => 2024-03-11 20:11:18 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-new-injection-molding-handbook-tells-designers-and-engineers-success-factors-for-part-design-and-resin-selection/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [80] => WP_Post Object ( [ID] => 2433 [post_author] => 3 [post_date] => 2017-03-29 17:05:00 [post_date_gmt] => 2017-03-29 22:05:00 [post_content] =>Today, so many different parts are being injection molded. These parts include laptop and mobile phone cases, medical and military electronic components, and a variety of other materials across industrial, consumer and specialty markets. Because of this, EMI and RFI shielding is becoming increasingly important.
Proper shielding for injection molded component parts is necessary to meet regulatory requirements as well as ensure continued, reliable performance.
Plastic parts are non-conductive. As such, they are not able to provide any sort of shielding on their own. This shielding works both ways. First, it prevents EM and RF from being emitted from devices housed within the injection molded cases. The shielding will also prevent outside waves from penetrating and interfering with the device’s operation.
Sometimes there is confusion over what is needed for a specific part or component. The reality is that the terms—to an extent—are so similar that they can be interchangeable, but there is a difference to note.
EMI stands for electromagnetic interference. EMI is defined as an electrical or electronic disturbance. This can be a naturally occurring phenomenon or something man-made. This disturbance is going to cause undesirable effects such as interruption or degradation of service.
RFI is short for radio frequency interference. The specific difference has a lot to do with the frequency at which electrical distortions fall between. So, all RFI is EMI, but not all EMI is RFI. RFI can be found at any frequency shared by radio transmission ranges—typically more than 1kHz to 10 GHz. Conducted RFI is usually going to be at the lower end of the spectrum, or, less than 30 MHz.
Virtually everything with an electrical signal causes some level of EMI or RFI interference. Fluorescent lights, radios, microprocessors, electric switches, networking equipment, phone lines, power cords, headphones, wireless devices, speakers and so much more. The problem used to be a lot more recognizable until we began working with different frequencies, power levels and better shielding.
If you set something near your television or laptop and see the screen dim, flicker, or otherwise distort, that is an example of EMI/RFI interference. Another example could be if you are having poor Internet connection speeds and you move the physical location of your router and the speed gets better—this is caused by a form of EMI/RFI. Static on a mobile call? It’s very likely the same problem. There are many common examples we all experience in our everyday lives.
There are some plastics that can be made condusctive with certain additives included. This is, however, very costly and therefore limited in use. Typically, plastic itself is not conductive. Because it’s not conductive, plastic cannot provide EMI / RFI shielding to prevent interference with your device or prevent your device from causing interference.
Conductive coatings solve this problem by adding shielding to injection molded components. This method has been in use for more than two decades and has consistently proven to be a reliable and cost effective means of shielding plastic parts. Conductive coatings are also favored for their lack of volume utilization within the unit.
Three key factors to consider when designing a part that will need EMI / RFI shielding are resin selection, mechanical/functional design and specific shielding requirements. Either the entire part or selective portion(s) of the part can be plated.
One of the first methods for adding conductive coatings for shielding is called electroless plating. Electroless plating is used to deposit thin metal coatings, from 0.00004” (1.0 µm) to 0.0005” (12.5 µm). Parts will go through a process that includes a chemical etching (to make the part rough) and an activation step which deposits a catalyst onto the surface to prepare them for being covered (or plated) with a layer of copper. Overall, the material properties of the resins remain unchanged; only the surface layer of the parts are being affected in this process.
This method provides a uniform thickness for the copper layer on the part. This includes part recesses and holes. Some applications will require applying additional copper on top of the initial layer, which will enhance the shielding’s effectiveness. The copper can then be plated with tin, gold, or nickel for environmental, electrical, mechanical, or cosmetic reasons.
Electrolytic plating—also known as electroplating—is for applications where thicker conductive coatings are necessary. This process applies metals at a thickness between 0.0002” (5.0 µm) to 0.003” (75 µm) or more. Electroplating comes after electroless plating when enhancing a part’s RFI shielding, providing additional metals over the initial copper layer(s). These metals include chrome, copper, gold, nickel, silver and tin.
Electrolytic plating is a different process that costs less and takes less time than electroless plating. The trade-off is that the application is based on line-of-sight and allows for a wider variation of the metal application to the injection molded part.
One of the earliest and most important decisions you will need to make during the engineering stage is deciding which resin to use for a part that needs to be EMI shielded. The resins that are capable of undergoing this process are referred to as plateable resins. Other resins are called non-plateable resins. However, even non-plateable resins can go through an RFI shield plating process if they are mixed through a custom engineered resin process first.
Resins commonly selected for plating include:
Resins that are difficult to plate include:
For help with the design and manufacturing requirements of injection molded parts that need EMI / RFI shielding, contact the specialists at Ferriot today.
When working with an injection molding company, many do not offer final assembly services. If you do find a contract manufacturer you are planning on working with that can take care of final assembly tasks, there’s a host of questions you will need to ask them. During the vetting stage, here are five of the most important questions to ask your contract manufacturer about their final assembly services.
ISO 9001:2008 requires that the company be able to consistently meet customer requirements when manufacturing parts. Other ISO certifications have specific emphases. Is the contract manufacturer you plan on working with certified?
You want a team with specific qualities. Search for a team that has focused experience in the product that you’re working with, or find a company that has a wide breadth of knowledge. This ensures that your manufacturing partner will know how to adjust quickly to your parts. They will also have the ability to see the production through to completion without any confusion or other roadblocks. Manufacturers with less experience may not be great at managing problems as they arise.
This is very important, especially with larger production runs. You want to be sure that the assembler and finishing team you have selected can handle the scope of work you need. They should have no issues storing, working on and shipping parts. Your manufacturer should also have the space to handle high volume demands without leaving parts outside or unorganized.
Some companies have a lot of experience managing a variety of critical tasks to help get your final stage product out the door. Other questions to ask that will help you better understand their abilities include:
One of the key reasons organizations rely on contract manufacturers to carry out final assembly work is cost savings. To lower costs, you’ll want to ensure that everything can be done in one place. This will add savings when it comes to logistics because you won’t have to ship parts from one location to another.
You can also save by ensuring you have the right partner when problems arise. The team carrying your product through from initial injection mold to paint to finish assembly have become intimately familiar with the parts. They fully understand how the part is supposed to work and the best way to handle it. If something should happen, and issues with parts are detected during assembly, you will want a company that’s familiar with your needs. That way they can solve the issue to get back up and running, which saves you time and money.
To learn more about selecting the right contract manufacturing partner download our free Contract Manufacturing Guidelines Tip Sheet.
Manufacturers need to be confident that they are providing their customers with quality products that meet agreed upon and necessary specifications. This is where a product quality audit (PQA) comes into play.
There are a number of different PQAs including the final quality audit (FQA), out of box audit (OBA) and others. The specific business needs will determine which kind of quality audit is best for your products.
There are three key ways for an audit to be conducted.
Read on to learn more about why you should run a PQA and how to ensure you have total quality management in place to get the results you desire.
When we discuss product quality audit it’s common to focus on the end product. However, other types of audits are important for a manufacturer to carry out as well. If you are using a contract manufacturer, you will want to be sure they are capable of handling product quality audits as well as surpassing expectations during process, management and other forms of audits.
The product quality audit steps and requirements should be decided upon before the manufacturing process begins. This would include designers and engineers working together with production managers to set reasonable expectations based on design, materials, manufacturing methods, machines being used and other criteria.
While injection molding custom parts, there are a number of items to review during a PQA. These may include wall thickness, orifice or cavity dimensions, coloration or finish, and any sort of strength/pressure/flex test that is required.
These steps should be completed before moving forward to final assembly. Final assembly and paint work will be done after the initial product audit, but then should also include its own product audit or FQA. This would include verifying functionality, flow, appearance, etc.
There are a number of reasons manufacturers should be carrying out quality audits for parts and assemblies. First, the part is designed for certain functions. If the part cannot perform those functions, it is defective. If it cannot withstand pressure, flex, or environmental tests, it will not last long in the field.
While some components are relatively innocuous—an ink pen tube, for example—other products are responsible for the safety and life of people who depend on them. If those products do not meet required specifications or perform as intended, it could cause grievous injury or even death.
Aside from that very serious (and legal) responsibility, manufacturers want to be sure they are producing quality parts because they do not want to handle an influx of returns and recalls. Such processes are costly in at least six ways:
Work closely with your contract manufacturer. There is a partnership where each of you is relying upon the other for success. They should be able to provide you with useful guidance regarding product quality audits and total quality management from their years of experience. They should also be fully familiar and comfortable with your company’s design and specifications. Never select a contract manufacturer that doesn’t clearly manage quality audits throughout the production process.
To learn how to get the most from your relationship with an injection molding contract manufacturer, download our free guide—Designing Injection Molded Parts: A Handbook for Designers & Engineers. Or, if you prefer, call us at (330) 786-3000 for immediate assistance.
Over the years, we have worked with a variety of different companies that all had different needs. This experience often lead us to discover interesting questions. When that happens, we always try to pass along the information, because we want customers to be knowledgeable and prepared.
Did you know that not all contract manufacturers do final product testing? Sure, they may carry out fit and function tests in the prototype stages, but they don’t go much further after that. It is an important part of proper quality control and your injection molding and assembly team should be carrying out tests throughout production runs at different points in the process.
Read on to learn more about how you can ensure that your manufacturing partner is taking all the right steps during and after production.
Without carrying out finished product tests, crucial elements can be missed. For example, everything may fit together, but a part could have become sheared during the assembly process. It is also possible for a part to get stuck in place during anodization, electroplating, or painting. There is also a chance for part failure, particularly with more complex plastic molded parts. Everything may have looked great on the design, but once the walls and cavities have settled and cooled, there is a chance for physical part failure.
You simply cannot tell these sorts of things without going through those additional testing steps.
There are a lot of companies out there with sterling reviews. You look and people only say good things about them on social media and company controlled pages. There never seems to be an issue. That right there should raise a red flag. Mistakes happen. It’s a fact of life.
The impressive part about a company is not that that everything is seemingly perfect, but more what action they take when production doesn’t go according to plan. To find out if your contract manufacturing partner is prepared by considering the following questions:
Different industries have different standards of testing and validation. You’ll want to know whether the contract manufacturer you’re working with is certified in the proper testing standards needed for your business. You should also ensure that they’ve kept up to date on the latest advancements with industry standards. You can verify this information by checking with the contract manufacturer and the certifying organization.
Ferriot is certified in a variety of standards and we work with companies in many industries including automotive, industrial, medical and more. Contact us for more details on how we can help you keep costs down and deliver on time. And, for best practices to minimize part costs without compromising your design goals download our free guide, Seven Ways to Cut Costs on Injection Molded Parts.
As we look to a new year, with a new president, it’s an excellent time to take stock of the U.S. manufacturing industry and where it’s headed. With a recent report from The Institute for Supply Management (ISM) showing the manufacturing index at the highest level since 2014, chances are it’s going to be a good year.
For some insight into this year’s trends, we turn to Printing Impressions and their article about what to watch out for in 2017. Some of the predictions include:
One category we find particularly interesting is the projected increase in custom manufacturing. While the article suggests that advances in printing technologies will offer opportunities for an increase in short production runs, we also believe that custom injection molding manufacturers will play a role in this trend. Contract manufacturers offer flexible options and experienced guidance for prototyping and low-volume productions that may be more affordable than 3D printing. Also, compared to 3D printing injection molders offer a wider selection of materials options.
For more insight on all the predicted trends read the full article on piworld.com: Manufacturing Trends to Watch in 2017
To learn how to get the most from your relationship with a contract manufacturer, download our free guide—Designing Injection Molded Parts: A Handbook for Designers & Engineers. Or, if you prefer, call us at (888) 667-0796 for immediate assistance.
No matter how much experience a person has and no matter how hard they try, there comes a point when we must all accept that we are only human. Mistakes can be made. This is one of the reasons it pays to have a final assembly service provider that understands your industry and end goals.
Making these mistakes when choosing a final assembly service bureau can be detrimental in cost overruns, delays and even recalls. Read on to learn how to avoid these potential barriers to success and profits.
Again, we are all human—even engineers. If your team of industrial engineers and design experts have looked over all the schematics and everything seems perfect, it is still a smart idea to have one last set of eyes to review the design.
A final assembly partner with engineers on their team has people who are involved with every aspect of production. Those people know how processes work in practical application, rather than just in theory. They are more familiar with specs and tolerances than those who are not familiar with finishing operations for final assembly.
These design engineers will catch errors others will others will commonly miss. Contract manufacturers that don’t offer this type of final assembly service skip an important step. This means that issues with clearances, solder bridging or incompatibility could go unnoticed.
Does this sound familiar? Everything on the CAD file looks great. Engineers from every team have signed off on the design. Production has begun and everything is going great. Then, something happens. There could be a shipping delay. There may be a defect with a shipment of components. Any number of issues can crop up when putting together complex, or even simple, assemblies.
An assembly service provider who also has parts sourcing capabilities is going to help make sure everything goes smoothly. First, they work with reliable sources and have a steady stream of incoming parts. Second, if something does happen, they have the ability to quickly make arrangements to keep production moving forward. This is possible because they have relationships and experience in the parts business that allows them to reroute orders, expedite new orders and otherwise avoid unfortunate delays that can cost you money.
It is not always the easiest thing to do, but press your assembly provider for details on what the different processes are to completely manufacture and assemble your components. You want someone who can do as much work in-house as possible.
This avoids delays due to shipping, other plants’ shutting down, or any number of additional issues that can be caused when your parts are in the hands of someone you are unfamiliar with.
From Pad printing to hot stamping to shielding and painting, you can rely on Ferriot and our more than 80 years of experience in the manufacturing business. If you are looking for the most economic and smooth transition for getting parts made, assembled and shipped, you owe it to yourself and your company to contact us today.
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Ensuring an injection molded product achieves its full potential demands careful planning. Much of this planning requires close cooperation between the engineer responsible for the design and development of the part and the injection molding contract manufacturer. The relationship between an engineer and a manufacturer will depend on a variety of factors, including the in-house resources available to the engineer and the level of assistance the contract manufacturing partner is equipped to provide.
If you’re an engineer, start with the following questions to ensure you’re making the most of your working relationship with your contract manufacturer.
If you’ve been working with the same partner for a long time, it’s easy to overlook resources and capabilities you’ve never taken advantage of before, such as:
Don’t hesitate to ask “what’s new,” even if you think you already know everything available from your contract manufacturing vendor.
Depending on your needs, you could have a variety of goals for production. Consider the following examples:
Maybe it’s some, or, all of these goals. Whatever matters most to you, make certain it’s spelled out clearly to your injection molding contract manufacturer, both verbally and in writing.
Particular part geometries can be difficult to injection mold. Some sizes, shapes and wall thicknesses can make the part especially prone to warpage, bowing and other defects. For example, unless properly placed and sized, features like snaps, undercuts, bosses, ribs, windows, etc., can complicate the molding process and increase costs unnecessarily.
Ask your manufacturer for guidance before you create a part design that will be difficult to mold or that might increase the part’s price.
Before your CM recommends a resin to be used to mold your product, discuss the key physical attributes that your end product requires. This discussion should include:
Identifying these attributes early will speed up the specification process.
Industrial injection molding operations have equipment that is most economical for parts within a minimum and maximum size range. Depending on the product, some facilities might be unable to produce a specific part due to the limitations of the equipment they have available. In addition, it is important to consider experience with different process technologies that can be applied to mold better quality parts.
For example, external gas-assist injection molding can be used to achieve sink free surfaces on thin-wall applications as well as for large flat parts such as enclosures, fascias and grilles.
Creating injection molded parts demands the use of a variety of testing and analysis techniques, both before the tooling is developed and afterward. The greater the precision achieved during the early test/analysis phase, the better. Time spent at this early stage saves money and rework later. Ask your injection molder about pre-tooling testing and analysis tools like these:
Confirm early that your contract manufacturing partner has the equipment and experience necessary to perform whatever tests are needed to determine whether a prototype part is ready to move into production. Depending on the part and how it will be used, this could include evaluations of drop or crash performance, low/high temperature properties, burst strength, static dissipation, wear resistance, moisture resistance, durability, structural compatibility, light transmission, shielding performance, sound dampening performance, part density, knit line strength, cracking resistance, or many others.
To learn how to get the most from your relationship with a contract manufacturer, download our free guide—Designing Injection Molded Parts: A Handbook for Designers & Engineers. Or, if you prefer, call us at (330) 786-3000 for immediate assistance.
Is there something else you’re looking for from your manufacturing relationship? Tell us about it in the below comments.
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You’re thinking about making an injection molded part for your product. You want your part to be everything you hoped it would be, and it you want it to succeed in the world, long after your involvement in the project ends. Here are three ways you can conceive and deliver a great injection molded part.
You’d probably be surprised to learn that liability concerns drive many aspects of part design and production. It stands to reason that with so many product recalls in the news, companies are right to focus on the safety and reliability of the products they make. Reducing a company’s risk exposure and ensuring that end users are protected be
gins with concept development, all the way through to the design and manufacture of the injection molded part. This is the responsibility of every person involved in the production of a part.
In general, when a mission-critical molded product fails, it’s the OEM who assumes responsibility for the outcomes. This is especially true for medical products. That’s why the mindset for the manufacture of medical products of all types tends toward a risk-averse, conservative approach. Medical OEMs are looking for contract manufacturers who have experience with various ISO compliance standards, certifications, and familiarity with industry regulations.
Tip: If this is your first time at the injection molding rodeo, get to know your legal team early on in the process. They’ll be your partners during the development of an injection molded part, from conception to delivery.
Before you fire up your design software to crank out some CAD models, be sure to spend a long time detailing all the other aspects of your injection molded part. Where will it live, how long will it live, what will it be made of, and will it be profitable? Specifically, you and the team will:
a) There aren’t too many large-scale industrial resin producers in the market, so it’s a small world;
b) Environmental and risk factors have already been assessed and approved by the OEM's legal and quality team. (Remember when we said legal review was important?)
After you have the right concept and you’ve planned out how your part will live in the world, it’s time to bring it to life. A metal tool must be created that will be used to produce your parts. This is the object into which liquid resin is injected. In almost all cases, the customer will, for lack of a better term, “contract” with Ferriot to build a tool as part of the production of their injection molded part. On a handful of occasions, the manufacturer has supplied the tool directly to us. However, when multiple entities are involved in transferring a tool, the risk for error is increased. That’s why we prefer to keep this activity in-house.
Fabrication of the tool takes place domestically or overseas, depending on the customers desires and requirements. Ferriot will be responsible for determining how the tool is to be built and will ensure conformance to the customer's requirements. Once the tool is built, product samples are produced. If the tool has been transferred, Ferriot will produce a first article from the tool itself.
During the scope and evaluation process, the Ferriot engineering team will have used CAD data to develop key inspection criteria. This could be five key specifications, or it could be as many as thirty, depending on the complexity of the part. Using the first article off of the tool, the part is evaluated using these inspection criteria. It’s Ferriot’s responsibility to ensure this entire process happens smoothly. This is why partnering with the right contract manufacturer makes all the difference.
After the tool and first articles pass inspection, you’re ready to start making molded parts in quantity. If you plan well, each warm, plastic molded part that rolls off the production line will embody the characteristics you’d hoped for, and will be ready to fulfill its purpose in the world.
For a detailed paper on how injection molded parts are produced, download our PDF, "How Injection Molding Happens: The Step by Step Production of a Medical Device Part." Click the image to get the paper:
If you’re ready to ask specific questions about your injection molded parts development process, complete a request for quote form. Or, if you prefer, call us at (330) 786-3000 for immediate attention.
[post_title] => What To Expect When You're Expecting an Injection Molded Part [post_excerpt] => A high-level overview of the production process for an injection molded part. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => what-to-expect-for-injection-molded-part-production [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-what-to-expect-for-injection-molded-part-production/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [88] => WP_Post Object ( [ID] => 2452 [post_author] => 3 [post_date] => 2016-10-25 19:33:00 [post_date_gmt] => 2016-10-26 00:33:00 [post_content] =>Ferriot, Inc. has been around for more than 80 years and boasts a proud tradition of being a family-owned business. The company was recently recognized with a special award during the 2016 Smart Business Family Business Conference. The annual conference is a result of the partnership between Smart Business and Cuyahoga Community College (Tri-C), and features an interactive workshop format to discuss how family businesses can plan for a smooth transition.
This year, Craig Ferriot was awarded the 2016 Family Business Achievement Award, showcasing the company’s dedication to excellence and the local community.
Ferriot, Inc. has come a long way since three brothers started their machining business back in 1929. Five generations later, the company continues to grow. Currently, the company employees three generations of the family that started it all.
Craig and his team of 120 employees are leading the way with injection molding production for a wide variety of businesses, including those who manufacture consumer products, automotive, medical devices, and more.
The company focuses on being able to deliver big--through smart investments in technology, processes, and people--while still remaining small. This allows them to be both agile and lean, able to help their growing customer base in varying and fluctuating markets.
Ferriot offers the full array of necessary services for their OEM customers. This helps to ensure end-to-end compatibility and heightened sourcing quality. Ferriot’s wide range of experience has made them the go-to contract manufacturer for many businesses.
Smarter, more efficient manufacturing and assembly processes are the key to Ferriot’s continued success. This requires the team to stay up-to-date with the latest technologies and manufacturing techniques.
The award highlights the role that innovative, family-owned businesses play in their local economic and educational landscape. Tri-C is a nationally recognized, leading educational institution with a strong commitment to preparing today’s students for tomorrow’s workforce. They also work to build the surrounding communities both economically and culturally. More than 85 percent of Tri-C’s students continue to live and work in the area after graduation. "We know and understand that family businesses are an important part of the fabric of our community, and we remain committed to helping family businesses succeed and thrive," says Alex Johnson, Ph.D., president of Cuyahoga Community College.
As a kid I had a toy that purported to answer questions about the future. Wouldn’t it be great if we had a Magic 8 Ball® to answer life’s big questions? Should I marry this person? Should I buy this house? We would be able to make the decisions that get the happiest results.
While this is just a fantasy, when it comes to custom injection molding, actually there is a way to predict the future using plastic injection-molding simulation software. Enter the geometry of the part (via a CAD model), specify parameters such as the type of resin, locations of the feed system and vents, injection pressure and temperature, and then watch what happens. The goal is to anticipate problems via simulation, without incurring the significant cost of creating a mold. When we review the results, we may tweak certain parameters of the molding process and then run the simulation again. By optimizing the tool design, we can improve part quality, shorten cycle times, and above all, avoid the need to rework a mold. If necessary, we work with our customer to modify the design and resin selection to achieve the best results.
Here is a rundown of the useful ways simulation software can improve your design and lower manufacturing costs.
Injection pressure. The software predicts the injection pressure at switch over, which is usually 99% of complete fill. Lower pressure is better as it facilitates manufacturing.
Cooling time. As the animation continues, we see the part cool. Colors indicate the various temperature ranges. Knowing how the molded part cools is helpful in specifying the packing/pressure hold time and predicting the speed of manufacturing.
Temperature at the flow front. As the resin fills the mold, the resin is cooling. You don’t want resin in areas of the mold to cool and harden before the rest of the part is filled, because that could introduce quality issues. The software predicts the temperature drop at the flow front. This type of information helps us strike a balance between fill time, injection pressure and other key process parameters.
There are even more ways to use the software, but I think you get the point. Obviously, simulation software is no child’s toy. It is a powerful tool for reducing cost on your injection molded project. Consider involving a molding expert who can assist you with this type of analysis.
Using software is only one way to save money on your project. There are several more, explained in our guide, “Seven Ways to Cut Costs on Injection Molded Parts.” Click the button to download your free PDF tip sheet.
If you’re ready to ask specific questions about your injection molded parts development process, complete a request for quote form. Or, if you prefer, call us at (330) 786-3000 for immediate attention.
(By the way, the lawyers want me to tell you that Magic 8 Ball® is a registered trademark of Mattel. Moldflow® is a trademark of Autodesk, Inc.) [post_title] => Avoid Molding Mistakes with Injection Molding Simulations [post_excerpt] => When it comes to custom injection molding, there is a way to predict the future using plastic injection-molding simulation software--and it'll save you money. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => avoid-molding-mistakes-with-injection-molding-simulations [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-avoid-molding-mistakes-with-injection-molding-simulations/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [90] => WP_Post Object ( [ID] => 2459 [post_author] => 3 [post_date] => 2016-09-02 10:00:00 [post_date_gmt] => 2016-09-02 15:00:00 [post_content] =>Creating a successful injection molded component is never a solo accomplishment – it involves multiple people with a range of expertise. One of the most important areas of expertise is the selection of the resin to be used. You’ll want the resin that best suits your design goals, performance specifications and budget—and a great team of injection molding experts to help you engineer your solution. Here is a quick overview of the 12 steps you and your team can employ as you think about the right plastic for your project:
Analyze part geometry. Part size, shape and wall thickness could make the part especially prone to warpage, bow, and other design issues. The sooner our engineers can review the part’s configuration with Moldflow® analysis and suggest changes to optimize its moldability, the earlier we can begin to narrow the list of appropriate resins. (Moldflow is plastic injection molding simulation software that helps us determine the best design.)To streamline this resin selection process and move components into production as seamlessly as possible, Ferriot has developed an Injection Molding Resin Selection Workbook. Click the button to download your free PDF.
If you’re ready to ask specific questions about your injection molded parts development process, complete a request for quote form. Or, if you prefer, call us at (330) 786-3000 for immediate attention.
[post_title] => 12 Steps for Choosing the Right Injection Molding Resin for Your Part [post_excerpt] => Choose the best injection molding resin to make your part. Use this worksheet to properly scope your design and execute your part. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => 12-steps-for-choosing-the-right-injection-molding-resin-for-your-part [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-12-steps-for-choosing-the-right-injection-molding-resin-for-your-part/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [91] => WP_Post Object ( [ID] => 2461 [post_author] => 3 [post_date] => 2016-07-14 16:00:00 [post_date_gmt] => 2016-07-14 21:00:00 [post_content] =>Insert molding is another type of injection molding (IM) process: In this process an insert is placed in the mold either manually or through automation before injecting resin material around it to secure it in place. This insert can be made of different types of metal, including steel and aluminum and/or non-metal components. In some instances, the inserts are simple designs such as electrical leads, fastener, pins, or sheet metal. Other times, wire meshes and plates are used as inserts, strengthening the final product of the injection molded unit. These are not the only options for injection molded inserts—more complex designs can also be molded as inserts.
By molding around inserts, this technique of injection molding can reduce assembly and labor costs as compared with incorporating the elements in final assembly. Because the insert is efficiently placed as part of the IM process instead of being placed after molding, the part can also be made smaller. No fasteners or mating joints are required. Design flexibility is a key benefit to insert molding as well as other overall improvements: increased component strength and decreased part size and weight.
The tolerance requirements for molding around an insert are relatively tight. In this process, the resins are being molded around a pre-existing unit. If the mold is off by even a fraction of a millimeter, the part will not function as intended. Ferriot’s design and engineering team works closely with our clients to ensure that the strictest tolerances are consistently produced. We also have several solid partnerships with vendors to provide on-spec metal (and non-metal) inserts for injection molding. Realizing all the benefits this type of IM technique can offer means getting it right—with the right design partner.
Verifying the design and tolerances for the component(s) to be injection molded is key, but there are other things to consider, too. The insert must be able to withstand the extreme temperatures and high pressure of the injection molding process. For this reason, it is imperative that you are familiar with the insert provider and their ability to maintain consistent quality. Consider, too, the initial tooling design cost could be increased due to the fact that the molds will need a way to “hold on” to the inserts until the resin can be injected. Sometimes, tool designs leverage the benefits of bosses or undercuts to offer enhanced retention strength. Creating a reliable way of doing this that lasts the entire duration of the project run can be tricky. Our design and engineering team will work with you to help meet your specific needs while keeping costs down.
If you’re considering a specific project, you may be wondering:
If you’re ready to discuss your project details, contact us for a quote.
[post_title] => The Benefits of Insert Molding in the Injection Molding Process [post_excerpt] => What are the benefits of insert molding over other types of injection molding? Can it make your parts better? Can it save you money? Click here to find out now! [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => the-benefits-of-insert-molding [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-the-benefits-of-insert-molding/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [92] => WP_Post Object ( [ID] => 2463 [post_author] => 3 [post_date] => 2016-06-29 14:30:00 [post_date_gmt] => 2016-06-29 19:30:00 [post_content] => Ferriot, Inc. was featured in the July/August issue of Manufacturing Today magazine. The full article discusses three key areas that assure the success of any contract manufacturing endeavor. Here's what you need to know if you're looking for the best manufacturing partner for your unique assembly challenges.
incredibly complex, riddled with the potential for derailment or missed deadlines. That's why it's important to select a contract manufacturer with the right expertise who can drive the process from start to finish. For thermoplastic injection molding of engineered resins that process begins with mold creation. From there, an ideal partner will take the client through supply-line development and management, process qualification, product testing and final assembly. Handling the drop shipping of the finished material is a final service that frees up client time and attention, and knowing that the job will be delivered properly and on time is invaluable. "One-stop shopping" with an experienced partner delivers peace-of-mind as well as convenience and cost efficiency.
Choosing a contract manufacturer with the expertise to guide a client from end-to-end becomes particularly important for specialty operations such as insert molding, high pressure structural foam molding, gas-assist molding, and overmolding. Even more complexity is introduced when additional finishing is required:
[post_title] => Three Ways a Full-Service Contract Manufacturer Adds Value
[post_excerpt] => What should your contract manufacturer bring to the table? Here's what you need to know if you're looking for the right total manufacturing partner.
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[post_content] => Decorative metallic coatings allow plastic parts to function as lightweight, economical alternatives to metals in a variety of applications (i.e. automotive, appliance, business machines, etc.). One such process is electroplating, which provides a high-quality, durable finish to plastic. Today, plating grades of ABS and PC ABS meet the stringent performance requirements of automotive and appliance applications.
This article focuses on two important front end processes, plastic part design and injection molding specifically for electroplating. Both significantly influence the success when plating a plastic part.
Let’s begin by talking about plastic part design and what should be considered when designing and building a plastic injection mold. Keep in mind, that defects on highly cosmetic surfaces will be more pronounced after electroplating. Following best design practices will help optimize the appearance and keep rejects at a minimum:
These key points discuss how to best optimize the injection molding process for improved plating adhesion and end-use performance:
There are many subtle nuances to proper processing of plastic parts to be electroplated. Ferriot has many years of experience in the molding, decorating and assembly of plastic products and understands the steps necessary to insure success in producing electroplated plastics.
Here at Ferriot, we are proud to be a leader in thermoplastic injection molding since the 1940s. Our clients turn to us for professional assistance with contract manufacturing, custom injection molding, painting, and assembly. Structural foam is one of several injection molding processes we offer.
Traditional injection molding is typically done in two stages. There’s an injection stage where melted thermoplastic is injected into a mold, and a packing stage where pressure is built and the plastic is formed into the shape of the mold. In structural foam molding, the injection stage is basically the same, but the packing stage is augmented by a chemical blowing agent mixed with the material. That chemical blowing agent is triggered by heat and expands the material by creating a microcellular structure to form the part against the mold.
A part made using structural foam molding offers a number of advantages. They generally weigh less and aren’t as dense as similar parts manufactured using other processes. This is the end result of the blowing agent which, essentially, creates a thermoplastic foam within the mold. Actual weight savings can vary, but parts made using structural foam molding can be as much as 10% - 30% lighter than other parts, while retaining durability.
This process also scales well, allowing large or bulky parts to be manufactured while still retaining the superior production speed offered by injection molding. Structural foam parts can be finished by methods typically used for other plastics. The surface of a finished part is smooth offering the potential of easy cleaning, and can be painted over.
An additional benefit to parts manufactured using this process is part durability. As a result of the difference in process, parts have excellent stiffness-to-weight ratio.
We’ve been busy putting structural foam molding through its paces to manufacture a variety of parts, including a gasoline dispenser front facia for use at filling stations and the results have been everything we could have hoped for. Along with the durability offered by the new parts, the material options available for structural foam molding also means a finished product can be chemical resistant, offer electrical or thermal insulation, and can be developed for outdoor applications.
Think this might be an alternative solution for you? We encourage you to contact us to discover how Ferriot can benefit your business.
[post_title] => Expanding Options With Structural Foam Molding
[post_excerpt] => Structural foam offers an alternative to traditional injection molding.
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[post_content] => Recently, FirstMerit Bank’s magazine, Merit Matters, published an article featuring Ferriot, Inc.’s President Craig Ferriot. The article discusses Ferriot, Inc.’s history as well as how the legacy continues.
For more than 50 years, FirstMerit Bank has assisted Ferriot with all of its banking needs. One of the reasons that this relationship has endured, other than both being based in Akron, is due to the similarity in the two organizations’ values. Mutual feelings of trust and alignment have also played a large role in this continued partnership.
As Ferriot has continued to evolve and grow, FirstMerit has been there to support them through a diverse suite of financial tools. These tools include:
FirstMerit has “been top-notch in responding to our needs as a company. They work very hard to understand what our needs are, and they are excellent at delivering what they promise,” says Craig Ferriot. Another trait shared by both companies.
To read the featured article, and learn more about Ferriot, Inc.’s beginnings and future, please click on the button to download a printable version of the article.
[post_title] => Continuing a Legacy [post_excerpt] => Recently, FirstMerit Bank’s magazine, Merit Matters, published an article featuring Ferriot, Inc.’s President Craig Ferriot. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => continuing-a-legacy [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:19 [post_modified_gmt] => 2024-03-11 20:11:19 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-continuing-a-legacy/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [96] => WP_Post Object ( [ID] => 2474 [post_author] => 3 [post_date] => 2015-12-07 05:00:00 [post_date_gmt] => 2015-12-07 10:00:00 [post_content] =>
Akron, Ohio, December 7, 2015: Ferriot Inc., a custom injection molding and contract manufacturing company, has appointed Dave Harman to the management team to achieve sales initiatives in key markets. Dave joins Ferriot as Director of Sales and Marketing where he will oversee both Ferriot and its wholly owned subsidiary, American Original Building Products. Dave brings over 30 years’ experience in sales and sales management with Fortune 500 companies as well as small, family owned organizations. As a business owner, he fully understands a balance sheet and a P&L and how to make an operation run successfully. As a sales manager, he takes leadership and profitability seriously.
Already committed to a career in sales and sales management, Dave had developed a successful track record with experience in both the large corporate world as well as the small business arena with companies such as Conoco/Vista and Amresco. But it was Sandler’s systematic approach to selling and leadership that took his success to a different level. Learning and implementing the behaviors, attitudes, strategies and techniques available through Sandler’s model of on-going reinforcement training and coaching, Dave consistently, incrementally, and dramatically improved sales and profits.
After many years as a Sandler Training client, his passion for sales drove him to join the Sandler team to pursue his desire to help other sales and management teams grow in the areas of sales, leadership and professionalism. He is devoted to working with salespeople, sales managers, executives and business owners who are just as committed their own professional growth.
Craig Ferriot, President of Ferriot, Inc. said, “Dave brings a wealth of experience in the sales arena and with the increasing demand for exceptional support and service by our customers, his knowledge and leadership will provide the expertise that we are looking for as we continue to develop our sales team and grow our customer base.”
Ferriot Inc. is a full-service contract manufacturer and injection molder of engineered resins. Privately held since its founding in 1929, Ferriot employs veteran engineers and skilled technicians of the manufacturing and plastic injection molding industry. Ferriot’s contract manufacturing services include engineering, design, molding, sub- and finished assembly and delivery of components and finished products for a variety of industries including building and construction, medical, industrial, business machines, oil and gas, electronics and more.
Two major impact areas for product development engineers.Designing new products is a very tough job; there is so much to do and little time to make it happen. Speaking specifically about molded plastic parts, four critical areas usually blend together in successful product designs. The 3D part design, material selection, tool design / construction, and simulation /processing. If not impossible, it would be extremely difficult to find any one person who can do it all. This is why it is so important to have molding partners that can help share the weight of the new product development process.
Product development engineers usually lead the way in part design and material selection, but these activities can also be passed to suppliers in some cases. Brad Martin’s post on November 25th 2014, “7 Key Aspects to Identify When Designing Injection Molded Plastic Parts,” discusses some high level critical questions that need to be asked at the beginning of the part design process.
The second major impact area for product development engineers is material selection. Once you have summarized critical design requirements you can begin to narrow your list of preferred materials. This can be done by referring to your company standards, searching material databases, searching the internet, contacting your preferred raw material suppliers or contacting your molding partners. The goal would be to meet all your critical part requirements and to narrow the list down to a couple strong candidates for further consideration.
Once you have a preliminary part design and a few possible material selections you can now begin to accelerate the concurrent engineering process with your supplier and optimize your design.
Key outputs from the concurrent engineering process should be:
Contract manufacturers come in many shapes and sizes. Some are large international companies with sites around the world that are finely tuned lean manufacturing machines. Others serve a niche and may be an American Small Business.
The large international contract manufacturer is set up to make hundreds of thousands of the same product and do so extremely well. There are times that those large volume products require a machine that consumes or dispenses them. These machines themselves are a low volume, high mix build that is not attractive to same company but are part of the deal. The size of parts, right manufacturing processes, sources of supply, and order fulfillment process are not the same for the machine and the consumables.
This creates the need for a supplier to the large contract manufacturer to produce parts such as machine enclosures or panels that are part of a much larger machine. This could include more specific processes like structural foam injection molded panels, gas-assist injection molding to accomplish special cosmetic needs, or insert molding that will embed a hinge pin or metal plate.
These enclosures or ‘outside skins’ also need decorating. This could include painting, pad printing, or addition of decals.
Special functionality such as EMI/RFI shielding is also quite common with such enclosures.
While providing the parts and the variety of value-added services, it may also make sense to add other componentry so the large contract manufacturer is managing fewer SKUs.
When this is all put together, the supplier that starts with some primary parts, adds finishing operations and componentry and simplifies the works of their customer, the large contract manufacturer. Just like the contract manufacturer is simplifying the life of the OEM.
Ferriot has enjoyed its place in this process of supporting the large contract manufacturers and OEMs over the decades.
Keeping a competitive edge in today’s market requires speed and agility when launching new products. Time to market for new products has become further and further compressed. Early engagement with a full service plastics partner can steam-line your development process and accelerate your time to market.
Here are six ways a full-service plastics partner can help your business reduce time to market for new products.
Have you ever experienced making samples of a new product on a 3-D printer and then being told that the product was not manufacturable? By engaging a plastics partner in the initial stages of your design you can save hours of effort. A plastics expert can provide input on what design features are possible from a manufacturing standpoint. This will allow you to design with manufacturability in mind and save hours of effort by eliminating the number of design iterations required. A plastics partner should be in integral part of a collaborative process with all stakeholders in new product development.
Designing an injection mold is both an art… and a science. Working with experienced Tooling Engineers is critical to creating an optimal mold design and optimizing the development process. Experienced engineers will consider how best to accomplish all design aspects of a mold. A qualified engineer will consider options that include identifying actions to create part features, holes, recessed features, windows and inclusion of inserts. A well designed mold can eliminate additional steps in the manufacturing process later.
Picking an injection molding company that has multiple injection molding processes will improve your chances of getting the best process for your part.
These would include straight injection molding, structural foam molding, gas assist molding, insert molding and over-molding. Each process has its own attributes that will satisfy particular product needs. A qualified plastics partner can help you to identify the ideal method to provide a quality part.
Most plastic parts will require some form of finishing such as pad printing, ultrasonic insertion, hot stamping, painting or EMI/RFI shielding. Selecting a plastics processor that includes these operations under the same roof will provide the most efficient manufacturing process. This can take weeks out of the lead time to produce a finished part.
Utilizing a plastics partner that can also source components and provide assemblies can simplify the OEM’s manufacturing process and drive cost savings. By providing supply line development and management, your plastics partner can economically source materials from qualified suppliers, reducing supply chain risk for the OEM. Assembly capability under one roof provides cost savings by eliminating additional shipping and assembly cost.
Engaging with a plastics specialist can help your company achieve optimum efficiency and profit while producing quality parts. Whether you are taking a product from concept to completion or transferring an existing mold project, effective quality management practices are an important factor. A qualified plastics partner has procedures in place for mold, part and process qualification and has documented processes that will ensure production quality. Trained & experienced engineers will follow standard testing methodologies including FMEA methods and utilize the right testing equipment for part qualification.
Optimizing your new product development process is a strategic imperative where the first to market with a new product enjoys a competitive advantage. Engaging a qualified plastics partner early in the new product development process can help you to accelerate your time to market by saving time and investment cost and delivering a quality product.
.The above points should speak for themselves when it comes to making the production of your new plastic piece easier in the long run. By taking the time for due diligence in the early stages, you’ll not only save time and money – but you’ll be much more confident and secure that everything is done to your specifications for on-going production orders.
Painting plastics is not easy, as special paints are required to give your parts the desired finish and ensure it bonds well with the plastic. However, painting techniques have evolved over the years and there are several different means by which the plastic parts can be painted to meet any need. Below are two main reasons why plastic parts should be painted:
Completely unrelated to functionality, the details below discuss options if you are looking for a flawless finish.
If your pieces need to be uniform and you require a custom color, it will be less expensive and more pleasing to paint the pieces rather than create a custom resin. OEMs choose to use painted plastics because resins may not offer the desired effect or color.
When it comes to testing painted plastic molded parts, color uniformity is the main thing that comes to mind. Paint will enhance the appearance of the plastic and will help you to match custom colors exactly.
This is the idea of producing mass plastic products that have been tailored to your desires and needs. Producing a variety of colors in a molding press is impractical, particularly when the plastic colored parts that are required are small.
Paint helps to conceal the imperfections of the mold and/or surface conditions that are a result of the injection molding process or part geometry. Some of the imperfections include:
As a customer, you may want a higher gloss finish than the resin is capable of providing. Paints can achieve a wide range of gloss levels, which will make it easier to achieve your marketing objectives.
While painting not only allows for improved aesthetics, the functionality of your plastic part can be increased through painting, as described below:
Paint can improve protection of plastic molded parts from a broader range of chemicals and other substances that can stain it.
Most cleaning chemicals in the market today are harsh and can reduce the physical properties of some plastics over time. Paint helps to protect the plastic parts.
The smooth finish makes cleaning the plastic easy. There are no scratches or stains that would make it hard to clean or give dirt and dust a place to hide.
Paint makes the plastic surface harder so that it will not be as easily scratched, helping to avoid abrasions.
UV coating is a perfect choice if your plastic parts will be outside. A number of plastics are sensitive to exposure to sun, the ozone, salt, and acids. Paint will help to protect the plastic.
Understanding the effects of paint on plastics is a key to improving the appearance and performance of your molded plastic part.
Pad printing is an innovative and effective process for transferring a two-dimensional image onto a three-dimensional surface. It can also be a delicate process with numerous variables that can lead to an unsatisfactory image transfer if done incorrectly. My goal in this post, assuming the reader has a basic understanding of the pad printing process, is to touch on a few of the more frequently encountered problems that cause poor image transfer and how to troubleshoot them.
In my experience with pad printing, the three most commonly encountered problems that arise while printing on a job are as follows: an incomplete print or a print featuring excessive voids, distorted and blurred prints, and the pad carrying excess ink or dirt outside of the desired image. Before touching on the three said problems it is important to state that starting a job under ideal printing conditions and practicing preventative maintenance on your equipment is going to be the most important part of achieving good transfer and maintaining that good transfer over a period of time. Having clean blades, cups, pads, and clichés along with ink mixed to the vendor/manufacturer’s recommendations is vital to a successful start up. If good start up practices are taken and problems still arise, then hopefully the simple troubleshooting tips below will help.
If any job runs long enough you will eventually begin to see voids within the print or begin to see incomplete prints all together. This is due to the evaporation of the solvent, or “thinner” from the ink, which in turn makes the ink thick and resistant to a clean transfer. 85% of the time, the correct and the only needed course of action is to mix in more solvent. The other 15% of the time, when thinner is added and the poor print still persists or rapidly reemerges, there are a few possible solutions:
When ink is mixed correctly but the transfer is still flawed, then the silicone pad or the cliché are most likely the cause. Any bending, bowing, or abnormal curvature to an image that has been transferred can be attributed to the pad. When a pad strikes the cliché or the surface of a part too hard, the smashing of the pad will distort the print during transfer. The pad should only strike hard enough for a complete ink pick up and a complete ink transfer. Too much pressure runs the risk for distortion and too little pressure will lead to an incomplete print. The same problem can occur when the shape of the pad does not fit the contours of a part. Make sure manufacturers and suppliers are involved when new pads are made for new programs and that clean undamaged pads are used in production.
Just as detrimental as incorrectly handled ink and pads is a damaged cliché. Any scratch or knick deep enough for ink to seep into will be transferred over to an image if the pad strikes that particular area of the cliché. Precautions need to be taken to maintain the surface of clichés and prevent rust.
The above maintenance and troubleshooting recommendations should correct the three common issues mentioned above. If you encounter these problems in your pad printing process or other common issues leave us a comment below to share troubleshooting tips or questions.
There are many variables that impact the success of injection molding a good part. One of these variables is injection machine screw choice. When it comes to screw choice, choosing the right screw geometry for your project is crucial to success. It will ensure there is no material degradation and that the material will have been properly melted. This will result in less stress in the part, less scrap, and proper size and weight.
In today’s environment, injection molders need to be making parts as efficiently as possible in order to keep manufacturing costs down. Using the right injection screws for your customer’s parts will play a significant role in this. There are a few things you need to know first, such as how a screw works and how to match a screw to the type of polymer you plan to use.
The basic design of any injection molding screw has three zones along the length:
The feed section conveys the solid plastic pellets to the transition section where they are compressed by a change in screw geometry (the channel depth). This compression forces the pellets to melt through the action of pushing up against each other, which is called shear. The metering section then conveys the melt to the front of the screw, ready for injection into the mold cavity.
In the picture above you see a general purpose feed screw. If you are running polypropylene (PP) or polyethylene (PE) with no additives, this type of injection screw will work great. At Ferriot’s custom injection mold shop, we run polycarbonate (PC), Nylon, Delrin and blends of different polymers with fire retardant, UV stabilizers, glass filling and lubrication. (How they fit all that stuff into a little tiny pellet I will never know, but they do.)
When you try to run PC on a general purpose screw, the material will burn in the compression section of the screw. This is because it forces too much material into the compression section and causes too much shear heat and burns the material. You can make process changes to adjust for this by lowering the pressures and heat, but this will cost you cycle time. The correct screw design would have a short feed section, a long compression section and a short metering section. The long compression section is gentler on the material, so it eliminates burning.
There are many different configurations of feed screws – some for mixing color or additives and some for different materials. They have different coatings and are made of different materials and have flights and root sizes configured for specific situations. One piece of advice is to ask the people that make injection molding feed screws what will work best for the particular situation as they are very knowledgeable and have seen most process issues before. Material vendors are also an excellent resource for determining optimum screw configuration.
In today’s world of manufacturing and new product development, the need for fast-paced production and the existence of complex designs is greater than ever. Historically, manufacturers have depended on metal due to an existing wealth of metal knowledge, it’s strength and stiffness, perceived quality, and ideal properties related to electricity, UV performance, and chemical resistance. However, due to a fluctuating economy, high cost of goods, and smaller margins, the need for materials that can reduce weight, cost, and production time is huge.
Although metal-to-plastic conversion has been around for decades, many manufacturers, Commodity Managers, and engineers aren’t familiar with the benefits. With proper design, engineered plastics and high performance resins can be just as strong as metal. According to the American Society of Mechanical Engineers, “in general, companies can expect to achieve an overall cost savings of 25% to 50% by converting to plastic parts.
There are many factors that drive metal replacement, however the main three include:
When beginning the process of determining if metal replacement is the right move, we typically recommend utilizing DFMA (Design for Manufacture and Assembly) – a systematic approach for evaluating and generating product designs for ease of assembly and manufacture. The best time to use DFMA is when it can influence the conceptual stages of a product. For example, is there a potential for parts consolidation? Are there quality or ergonomic issues? Are the current assembly operations too complex or expensive? These are all important questions that help ensure you are taking a systems-solution approach, which is critical for successful plastic-to-metal conversion.
Plastics have been highly successful in replacing traditional materials in applications where they can provide value through improved performance at lower systems cost. Here are some of the benefits of replacing metal parts with plastic ones:
In summary, metal replacement is largely driven by system cost reduction. Plastics may offer additional performance advantages, such as weight reduction, impact improvement, and corrosion resistance. The most impactful metal replacement successes typically require a cross-functional team reviewing an entire subsystem, rather than a one-for-one replacement.
When I initially joined the building products industry in the year 1999 there were 30 + Manufacturers of Vinyl Siding… Fast forward to today, and it’s now down to 9… mostly through consolidation. It remains the #1 Choice for exterior cladding across the US, primarily due to its low cost and maintenance freedom. And it looks EXACTLY like it did in 1999, nothing has changed.
People have been driven to this product over the years because it was the closest thing to resemble wood, without having to paint it, stain it, or maintain it…
GOOD NEWS! You have an alternative… Injection Molded Polypropylene Siding, and here are 5 reasons why:
1. Curb Appeal: Next time you are driving down your street, take a look at the other homes. Do they look alike? Or at least similar? Polypropylene Siding is offered in 4 primary profiles: Traditional Cedar (most popular), Hand Split, Scallops (or Half Rounds), and Cape Cod. They can be used to cover the whole house, or simply as an accent. You can choose to use comparable or contrasting colors…it’s up to you!
2. Twice As Thick: On average, Polypropylene Siding is twice as thick as traditional vinyl siding. The added thickness provides better impact resistance against things such as hail and falling tree branches. The increased thickness adds weight to the product, making in more wind resistant, and therefore far less likely to blow off during a storm
3. Looks Like Wood: No really, it does! Deep, three dimensional wood grain provides the natural look of wood. The unique surface treatment of the mold removes the “gloss factor”, no more shiny looking plastic on your home!
4. No More Seams: An inherent problem with vinyl siding is that it can’t be installed properly without lapping the panels every 12 feet, therefore creating a visible vertical seam from the bottom to the top! In addition, vinyl siding expands and contracts as the seasons change (hot to cold, cold to hot). After a few years, this expansion and contraction often causes the seams to become even more apparent. Polypropylene Siding butts together, end to end, no need to lap! Various key widths make finding a seam virtually impossible.
5.Environmentally Friendly: Throughout its life cycle, Polypropylene Siding is more environmentally friendly and sustainable than vinyl siding, as well as most other exterior cladding products, and is 100% recyclable…
For most, the home is the biggest investment you and your family have. Most people side or re-side their home ONCE, so I encourage you to do it right the first time. Do yourself a favor and ask your contractor or builder to show you what’s available in Polypropylene Siding… you will be glad you did!
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Contract Manufacturing is a process that's about more than getting the parts you need. Here at Ferriot, we think of it as a partnership - and like any good partnership, that means working hard to ensure you get what you need.
Working with a contract manufacturer can allow for someone else to:
Manufacturing is complex, but we don't think it should be more complicated for you than it needs to be. Contact us today for more information about the contract manufacturing process and what we can do to solve your manufacturing problems.
One may wonder how it is possible for a plastics company located in Akron, Ohio to work with multi-national companies, serving their international market needs. For international companies that sell their product all over the globe, it does not make sense to invest in several production regions around the world. Instead, companies will partner with supply chain manufacturers in their own country to assist with subassemblies of their final product.
Supply chain manufacturing companies typically develop the part we’ve been contracted for and then we work to ship that part to the next facility for final assembly. This allows the company developing the product and the companies that work to build that product to act as more of a cohesive team. Since we are typically just a piece of the puzzle, attention to detail is crucial. Ordering, scheduling, tracking arrival times, and part inspection all play a role in the supply chain manufacturing process.
As new part qualification has become more sophisticated with First Article Inspections, Capability Studies, PFMEAs, etc., it is fastest and most efficient for the interaction with the New Product Development Team and Supplier to be in the same country. And Time-to-Market is forever being compressed.
Typically, it makes the most sense for a company to begin production where they plan to focus their new product development. If you’re a U.S.-based company, even if you sell your product elsewhere, it makes sense to work with a U.S.-based supply chain manufacturer. This allows the product development team and engineers to have easy access to the product and makes it easier to communicate with the supply chain management team.
Ferriot worked with a company that originally had both its innovation center and manufacturing facility based in California. The company moved the manufacturing to Costa Rica, however, with the innovation team still based in California, it made sense to keep the part-creation process in the U.S. as well. Ferriot ships that part to Costa Rica instead of California. This allows Ferriot to act as the specialist for the product, no matter where it has to go.
Are you a company working on product development in the US? If so, how do you handle your production?
To learn more about part creation, check out another blog post:
7 Key Aspects to Identify When Designing Injection Molded Parts
Several points should be taken into consideration when deciding to move injection molds from one supplier to another. The ideal solution is one in which the existing supplier, new supplier and customer are able to openly communicate while maintaining all customer deliverables in the process. However, when this is not possible, having a supplier that has experience with this type of transaction is extremely invaluable. There is no substitute for experience and comprehensive planning.
The following Mold Transfer Guidelines provide key points to consider when transferring molds:
This will cover the time necessary for the new supplier to put the essential provisions in place to transact future business uninterrupted. If the buffer is too small, it will put undue pressure on all parties, requiring alternative plans without sufficient time to execute.
Ample time should be given to:
Current Supplier/Customer
New Supplier
Both the new supplier and the customer should be on the same page as to what the expected deliverables are. This will establish the basic foundation from which the future relationship will be measured.
Key contacts should be made in the areas of Quality, Engineering, Manufacturing, Purchasing and Customer Service. This will streamline communications and insure the proper parties are aware of key deliverables.
It’s best to create boundary samples to avoid interpretation errors later on. The goal is to eliminate subjectivity as much as possible on both sides (supplier and customer).
If possible, retain the last “acceptable” shot (part and runner attached if applicable) off of each mold prior to transferring. This visual sample will provide key information to the new supplier in terms of current mold condition and customer acceptance standards. Preferably, parts should be untouched as they are molded prior to any secondary operations. This last shot should be inspected by the new supplier and matched against the customer’s current quality acceptance standards for conformance (i.e. all notes, dimensions and cosmetic attributes). Noted deviations will require customer disposition to assure all acceptance documentation matches the approved customer signed off “golden” sample.
Full disclosure is essential in meeting short and long-term goals. This should include past history as well as current status.
Jointly develop an action plan to resolve outstanding problems in accordance with future production needs and in order of importance. This will provide a successful foundation on which to build on.
For another post related to injection molding, check out:
7 Aspects to Identify When Designing Injection Molded Plastic Parts
Are you looking to design, develop, or produce a component that needs to be injection molded to complete the project? Do you know what key aspects you need to identify as you go to design molded plastics?
When going into this process, you need to identify both the obvious and not so obvious! Below are 7 items for you to consider before launching your project.
These are some of the things you must look at when deciding to injection mold a component. The key to a successful project launch is doing the homework up-front during the conception and design stage. Work with your engineering, molding vendor, resin suppliers, and other resources to properly identify and work through all aspects. THIS WILL LEAD TO A TIMELY AND SUCCESSFULLY PRODUCT LAUNCH!
Next, you will need to choose from a wide variety of types of resins. With these resin classes, you have a variety of products that gives you the flexibility to customize your needs. It also allows you to match the resin to the part design and moldability of the part.
In summary, when choosing a plastics resin to use in any type of injection molding applications, the possibilities are limitless. The list above just touches the edges of options for resin selection. By working with a Ferriot, Inc. representative, we will help you identify the correct and optimum resin to use in your applications. We benefit from having long-term partnerships with leaders in resin manufacturing. This allows us to optimize the success of your projects.
For another blog post by Brad, check out:
How Ferriot is Different from Other Plastics Manufacturers
Most engineers do not have ways to attach notes, tolerances, colors, etc. to a 3-D model, so they typically use the 2-D drawing to communicate important information. This blog post is an explanation of why 3-D CAD data is used as primary data and why it is critical for 2-D prints to not conflict with the source data.
The arrival of 3-D CAD modeling and direct CNC machining have allowed mold-makers to program the machining of molds directly from the 3-D model. This has significantly helped with saving time and money in both design and machining over old manual efforts in mold construction. Due to these technologies, most tool build times are in the sub-10 weeks range, as opposed to as much as twice that in the not too distant past.
New Technology = New ConsiderationsThese advancements in technology come with some challenges that must be taken into consideration.
Information on the 2-D part drawing cannot be allowed to trump data in the source 3-D model, an approach that is difficult to manage in today’s world because most CAD systems create the drawing from the source 3-D model. Indeed, the 3-D model defines the geometry of the part, but the 2-D part drawing is used to add specific information and notes about the part. Unfortunately these systems may allow for manual dimensional adjustments on the drawing that may not transfer back to the 3-D base model. And that’s where some problems enter: the designer of both the 3-D data and the 2-D print must resolve differences to clearly define to manufacturers what to produce.
Designers recognize the need for tolerances. In most cases, an equal plus and minus allowance is noted for specific dimensions on the 2-D print. In some instances, it was common practice to tolerance only one side of certain feature on a 2-D print. This approach would allow for expected variations in sizes while still allowing parts to fit together as intended – even at the extreme limits of tolerances. However, if the 3-D model were designed using this approach, the resulting mold and part would be built at the extreme limits of the available tolerance, actually making it difficult, if not impossible, to meet the expected tolerance, and certainly would not be able to attain statistical capability. The solution is to design to a nominal size and apply tolerances bi-laterally, thereby allowing tolerances seen in mold-making and injection molding, while still meeting design intent.
Statements like “2-D part drawings supersede 3-D design data” are impractical. When the 3-D design data is used to create the part, it has to be primary. Anything else is putting unreasonable responsibility on others to catch every difference between the two types of part definition.
This is a challenging but critical subject in part design. Because a mold is machined directly from 3-D CAD data, all draft angles and shut-off angles must be fully defined in the 3-D model. Again, notes on a 2-D drawing really aren’t able to be used in the mold build process – unless a mold designer modifies the 3-D part model – potentially a risky idea unless there is careful collaboration between the mold designer and the part designer.
To take full advantage of the technologies available it’s essential to address these challenges. In fact, in today’s world, it is unavoidable – it’s only a question of when. Early in the design stages is far better than if addressed at the start of the mold build, it is time consuming and potentially puts the part design at risk unless mold designers and part designers communicate carefully. Worse yet, if not properly addressed, there may very well be undue challenges in manufacturing, increased costs, and disappointing product performance.
Image courtesty of khunaspix via FreeDigitalPhotos.net
[post_title] => Resolving 3-D Data vs. 2-D Drawings for Part Definition [post_excerpt] => The benefits of using 3-D modeling for spec creation vs. 2-D drawings. [post_status] => publish [comment_status] => closed [ping_status] => closed [post_password] => [post_name] => resolving-3-d-data-vs-2-d-drawings-for-part-definition [to_ping] => [pinged] => [post_modified] => 2024-03-11 15:11:21 [post_modified_gmt] => 2024-03-11 20:11:21 [post_content_filtered] => [post_parent] => 0 [guid] => https://www.ferriot.com/blog/blog-resolving-3-d-data-vs-2-d-drawings-for-part-definition/ [menu_order] => 0 [post_type] => post [post_mime_type] => [comment_count] => 0 [filter] => raw ) [112] => WP_Post Object ( [ID] => 2505 [post_author] => 3 [post_date] => 2014-11-06 16:23:00 [post_date_gmt] => 2014-11-06 21:23:00 [post_content] =>To introduce you to the Ferriot blog, I wanted to give you some insight to the company. As the newest employee, I feel that I have set of fresh eyes on who Ferriot is and how they compare to the rest of the industry.
When the opportunity came for me to join Ferriot as a Senior Account Manager, several things convinced me it was the right place for me.
All of the things listed above were what made Ferriot an attractive employer. The vision was both evident and obvious, and I wanted to be part of this future.
There are other fastener-based technologies to hold parts together, but there are many advantages to the heat staking process including:
Heat staking works well with many difficult thermoplastics including the glass-filled plastics used in medical devices, automotive, appliances, telecom, electronics and consumer products.
The heat staking process can be used in a variety of applications including:
The most common resins used in heat staking are:
If you are designing a part that will be joined to another, contact Ferriot to determine if heat staking is the right solution for your project.
Learn more:
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Ferriot’s experienced engineers are here to guide you through every critical step in your injection molding journey, from concept to completion.
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