Consumer and Industrial markets cover a wide array of products, ranging from personal care to sports equipment to gears, pumps, sealing devices, electrical housings, and other vital parts for industrial applications. Although these products are incredibly diverse, they all rely on the same thing – injection molded precision and complex plastic parts.
At Proto-Cast, LLC we are able to collaborate with our customers from the inception of a design to providing the finished product, regardless of the volume or the material application.
Many consumer products begin at the entrepreneurial stage. At Proto-Cast, LLC we have worked with many entrepreneurs from concept, to design, to production. Many of these products are being enjoyed by consumers all over the world. To submit a Request for Quotation, please email us at email@example.com.
Case Study 1
A major manufacturer of electronic test equipment and measurement instruments for electrical power applications was experiencing structural failures in the field on their high voltage clamping device.
After researching material solutions, a Verton™ structural compound was selected with long glass fiber content. This material is a nylon resin with 35% long glass fiber content that delivers a balance between cost and performance in structural applications. It offers exceptional mechanical performance, combining rigidity with outstanding strength and resistance to impact failure. The part now is being shipped worldwide without any field failures!
Case Study 2
A manufacturer of patented retractable boat shades required several injection molded parts for a new design. The challenge was that four of the parts were cylindrical sleeves with keyways molded in each one. Normally this results in parts affected by shrinkage; due to the severe differences in wall thickness. Additional challenges were that the parts had to have superior strength along with complete resistance to the elements that boaters face.
Through careful and precise machine processing we were able to utilize a Delrin® 577 – 20% glass filled material to injection mold the cylindrical sleeves. The machine processing parameters were designed to reduce the overall part shrinkage therefore assuring the part remained concentric and functioned properly in the retractable outer tube. The 20% glass additive insures structural strength and a UV inhibitor supplies protection against the harsh elements. Now boaters throughout the world can enjoy the shade provided by this innovative product!
Case Study 3
A rail transportation company utilized a train brake lever that was manufactured using a forged metal process. The brake lever weighed a considerable amount and had to be carried at all times by the train engineer. Proto-Cast, LLC was contacted to determine whether the lever could be injection molded successfully, which would reduce the overall weight considerably.
Based on the geometry and thickness of the part, normal injection molding techniques and resins were not an option for this project. By using the additive Safoam®, a chemical foaming and nucleating agent, Proto-Cast, LLC found the solution. The Safoam® foaming agent blended with Verton™ Nylon6/6 with 50% long glass fiber filled resin worked the trick. The foaming agent helped with overall material and weight reduction allowing the part to be injection molded even with its current geometry. It improved cycle times, dimensional stability, and stiffness for this thick plastic part. The long glass fiber filled resin provided the strength needed to do the job. This solution solved the problem making it much easier to carry the lever at all times!
Case Study 4
A local distributor of guitar replacement parts wanted to develop their own branded line of seven different style guitar nuts. In order to limit the startup costs they preferred not to have to build multiple molds.
By utilizing an in house Proto-Cast, LLC owned mold base, we were able to design a family mold producing all seven parts in one cycle. This significantly reduced the initial investment by our customer and allowed them to achieve their dreams of entering the market with their own branded products. Now guitar enthusiasts all over the world can enjoy this product line from a new player in the market!
Case Study 5
An LED hardscape lighting manufacturer developed a new product that was designed with a channel cavity to house the LED board. To create this channel cavity utilizing injection molding, two through holes had to be created to allow the cavity core to be held in place during molding. These holes have to be sealed before assembly in order to withstand the heat from the LED lights and the exposure to the elements that outdoor hardscape lighting is subjected to.
Unable to design around the through holes that were required, the solution became simple. Create a cavity in the mold to produce a tapered plug that would then be ultrasonic welded into the hole after molding. Ultrasonic welding is a consistent method in joining thermoplastic materials and insures the integrity of the outcome. These LED paver lights can now be enjoyed by consumers everywhere as they enhance their living experience!