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Archive | Prototypes – Inventions

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Story Behind the Award-Winning Blow Molded Product The Pickup Tuck cargo organizer

Award-Winning Blow Molded Product

By John Doster, president, and owner
SPI Blow Molding LLC

Originally published in the August 2019 issues of The Journal of Blow Molding, a Publication of SPE

Back in 2011, a small group of former automotive engineers and designers came together to bring one specific, innovative idea to life. Last year, 2018, that product – dubbed the Pickup Tuck – earned multiple honors from SPE. It took first place in the Auto/Transportation category of the SPE Blow Molding Division’s Industrial Awards and first place in the Industrial Division Awards, as well as the People’s Choice Award in the Industrial Category. This strong showing qualified it for entry in the ANTEC Plastics for Life Parts competition in Detroit in March, where it won the contest’s Quality of Life Award. This is the story of how that concept came to life, from its invention by automotive engineers, through its design by experts — including consultants from 99Studio Inc. and Garrett Engineering Services — to its manufacture by SPI Blow Molding

Award-Winning Blow Molded Product – An Innovative Idea

Former automotive engineer Jim Todd mocked up a “truck trunk” designed to prevent loose items from sliding to the front of his pickup truck’s bed. Todd made his initial prototypes out of wood and PE sheet and made copies of his invention for interested friends. With help from colleagues, Carl Powell and Russ Sheehan, Todd modified his concept, creating a portable truck-bed barrier made up of plastic panels that can be folded flat and stored in the truck cab when not in use. The panels stretch out across the back of the truck, from the passenger’s side to the driver’s side. To take it to market, in early 2012, the three formed a new company, TSP Enterprises. Powell serves as president and CEO, while Sheehan became VP of prototype and manufacturing engineering and Todd is VP of product concept engineering. Todd’s portable cargo organizer is different from cargo boxes that were already on the market because it is a temporary “trunk” that can be installed and taken down in a matter of minutes without any tools. With the tailgate forming one side, the panels create a box, covering and protecting contents from the elements. The panels corral loose items near the tailgate, preventing them from sliding around the truck bed and making it easy to reach them without having to climb into the bed. If the tailgate is locked, the contents also are secured against theft. Todd, Sheehan, and Powell helped make the prototypes, and TSP worked toward larger volume production of the panels. An award-winning blow molded product is the result.

Looking for the Right Partners

In May 2017, TSP approached SPI Blow Molding, a small custom blow molding company, to get a quote to see if manufacturing the product was feasible. TSP’s challenge was to determine the right manufacturing process and partner to help it build the tools, manufacture the parts and assemble the components cost-effectively. It looked at injection molding, rotational molding and thermoforming before concluding that extrusion blow molding (EBM) would provide the best shot at success. TSP determined that EBM was the right fit because the expected volume would quickly surpass the ability of rotomolding to produce parts cost-effectively. Injection molding would have resulted in parts that had one show side and a lot of structural ribs on the other. Meanwhile, thermoforming didn’t provide the required structural strength. EBM presents the perfect balance of part weight, cycle time, tooling costs and finished part appearance. SPI’s management team recognized the product’s utility and potential, and TSP chose SPI because of the manufacturer’s technical expertise in blow molding flat panels and willingness to partner and provide additional leadership and capital. As part of the companies’ deal, SPI holds an equity position in TSP.

Getting the Manufacturer Involved Early

A key to TSP’s success was getting SPI involved early in the process. The blow molder employs about 32 full-time employees and operates on a 24-hour, five-day-a-week production schedule. It runs a wide variety of resins on 13 EBM machines that can handle shot sizes ranging from 1 pound to 42 pounds. Its portfolio includes products for the agriculture, automotive aftermarket, food and beverage, industrial, marine, medical, military, pet supply, and transportation industries. SPI has also been recognized by SPE for other award-winning blow molded products, including the HDPE Buzz Ball Football game table.

In addition to its blow molded parts, the Pickup Tuck has one injection molded component — a part that’s made by SPI Industries LLC, South Bend, Ind., the custom injection molding division of SPI.

Portable-Safety-Products-Online-shop

Find Portable Safety Products to Bulk Food Bins [for People and Pets!] in Our Online Shop

Portable Safety Products Online shop The Boys Safety barriers

Sorry product inventors and CAD engineers, we are not selling pre-made plastic molds in our online shop! What we are selling in the online shop is a variety of finished blow molded plastic products. Our online store includes portable safety products for safety at work, commercial bulk food bins for stores and markets and a large pet feeding and storage station, plus more to come. All of the products for sale on the SPI online shop were designated and made entirely in the USA.

All of the plastic molded products we feature in our online store are products SPI Industry manufactures. SPI Blow Molding has developed  and supported design of all the plastic part molds and has taken each item from concept to delivery. Online and brick and mortar retail outlets, including Amazon and Quality Elevator, carry some of our products. However, creating the online shop here on the moldedparts.com website just made sense for us. The online shop allows us to reach a larger audience who need these items. With the shop, the products can get into our customer’s hands more quickly. Current customers appreciate knowing they’ll get the quality and trust they expect from us and also enjoy hassle-free fulfillment. Orders are shipped within 1-2 business days of purchase.

Find Work and School Portable Safety Products on the SPI Online Shop

One of our most popular portable safety products includes The Boys Portable Safety Barricades. The Boys safety barricades are used in manufacturing, education, and any variety of public space that has occasion for collapsible safety barricades. Many manufacturing plants, office buildings, museums, zoos, and schools use “The Boys” to block off areas quickly and efficiently. The bright yellow plastic work man design has a friendly yet cautionary appearance especially suited to block kids safely away from unsafe areas.

Food Safe Plastic Bulk Bins and Dispensers

Two other popular products available in the SPI online shop include the Best Bins line of food safe, high quality, durable bulk food dispensers. From four gallon to eight-gallon sizes SPI’s Best Bin line is convenient and reliable bulk food dispensers used in retail specialty markets and grocery stores throughout the world.

SPI’s Pet Silo is currently only available for purchase here on the SPI online store. (also available on Amazon) The Pet Silo is a convenient animal food storage and dispenser used to hold 40 plus pounds of animal food. The design of the Pet Silo keeps other critters out and helps keep pets and animals food fresh. For homes, barns, chicken coops or backyard bird feeders, the Pet Silo is a neat and handy solution for the often messy job of pet food storage and dispensing.

Visit the SPI Online Store Today

We hope you find that our online store supports our mission to deliver ready-to-use quality parts on time at a fair price. SPI honors product inventors and enjoys supporting our customers by sharing these new inventions. If you have suggestions on ways we to enhance our online shop for your convenience, please contact us with your suggestions.

Thanks for stopping by SPI please contact us for all of your plastic injection moldings and blow molding needs.

Enter or mention PROMO CODE SAVE5 for a Special Introductory Discount. Expires 2/01/2018. Exclusions apply.

Temporary Plastic Safety Barricades

plastic safety barricades - the boys

Plastic safety barricades are used to block off areas from automotive or pedestrian traffic. From a single barricade to a continuous, obstruction free, fencing system, safety barricades provide clear guidance through work zones. Highly visible barricades prevent people from entering dangerous work zones.

Plastic safety barricades have increased in popularity

Safety barricades are used in emergencies and in situations when accidents have occurred or have the potential to occur. To ensure timely response, safety barricades that are lightweight, easily assembled, and easy to break down and store are very popular. Using plastic safety barricades meet these demands.

Plastic safety barricade uses

Plastic safety barricades are used heavily in road construction. Those of us in the midwest know orange barrel season all too well! The ever present orange plastic cones used to keep people in their driving lanes and out of off-limit areas are universal indicators of caution.

Most A-frame barricades traditionally constructed of wood are now entirely constructed of plastic. From the A-frame sides to the 2 x 4 rails with reflective caution stripes, these temporary plastic safety barricades are weather resistant, easy to install, break down, stack, and store until they are needed again.

Plastic safety systems also include temporary barricades for use inside buildings. The U.S. Occupational Safety and Health Administration offers guidelines for proper placement of barricades for protection of employees in all circumstances. From blocking off spills in cafeterias, closing off construction areas, blocking areas with limited access, warning of wet paint or wet floors, and many other precautionary instances, plastic safety barricades are in demand.

Benefits of Plastic Safety Barricades:

  • lightweight
  • durable
  • weather proof
  • damage resistant
  • color can be added during manufacturing process
  • stickers / labels can be applied
  • reusable – recyclable

free standing barricade -the boysSPI Blow Molding manufactures plastic safety barricades in a product for both interior and exterior safety situations called, “The Boys”. The Boys are a unique plastic safety barricade. Each ‘boy’ is all one piece and is 80% larger than the standard tent sign at 31” wide by 41” high. There is no set up time or any additional parts needed for use. If the area requires sectioning off, multiple boys can be used to form a temporary, solid wall, maintenance barricade by joining them at the hands. The unique ‘boy’ shape is 1,271 square inches of bright yellow plastic.

Each boy has ‘Caution: Out of Order’ emblazoned across the chest and a stop sign on the helmet. Quick deployment of the wire stand on the back of each boy allows it to be free-standing. The wire doesn’t get in the way when multiple boys are joined together to form a solid pedestrian barricade. Once the area is secure again the lightweight ‘boy’ folds flat for convenient storage.

Use of ‘The Boys’ and other plastic safety barricades in manufacturing plants, schools, offices, shopping centers and stores help keep visitors, children, personnel, contractors, and everyone in the facility safe. If you, or your organization, are looking for plastic safety barricades to alert people of hazardous situations with maximum visibility, ‘The Boys’ may be a good solution. As the manufacturer of ‘The Boys’ SPI is presenting them for purchase and delivery. Contact us today with any questions.

AcciDENTAL Masterpiece – New Product Inventions as Art

New Product Inventions as Art Blow molded Plastic Teeth

At SPI Industry molding facilities we are fascinated with the creativity and ingenuity of new product inventions.  Product developers create new designs of existing products as well as completely new products that are designed to make life easier, more efficient, safer, or more attractive for everyone. We see all new product inventions as art!

Recently, we received the most unique new plastic molding product request yet. SPI Injection Molding and SPI Blow Molding have produced a full gamut of new product inventions from plastic game pieces, plastic home decorations, plastic parts for appliances, molded parts for healthcare, and many more but this new plastic product concept was a first.  It wasn’t too unusual when the SPI Injection plant in South Bend, Indiana received a request to produce a large plastic tooth. What was unusual was the story behind the tooth.

plastic blow molded teethNew Product Inventions as Art Installations

The over 3000 molded plastic teeth were needed to create a toothquake! The toothquake was represented in the form of a 23’ x 26’ wide waterfall from the second story windows of an old Victorian that is home to the dental office of Dr. Demray. The tooth quake, we learned, was a result of the seismic activity that arose from the relocation of everybody’s favorite childhood messenger, the Tooth Fairy. The Tooth Fairy was staying at Dr. Demray’s offices temporarily while her new warehouse was being constructed. As each night passed, the increase in children’s teeth could no longer be contained and caused a toothquake Friday, June 17, 2016.

Dr. Demray was the most obvious choice when the Tooth Fairy was in need of temporary living quarters. Throughout his over 40 year career Dr. Demray’s mission has been to educate kids about good oral care. Demray’s commitment to share the message of bone preservation and dental care to children is also demonstrated in his cast of characters such as Betsy Floss and Miss Ginger Vitis. These characters participate in parades and school presentations sharing the importance of good oral care for kids. Ever seeking new ways to bring dental care education to the forefront, Dr. Demray decided an art installation of thousands of teeth in a cascading waterfall from his second story offices would be impactful. As a long time Art & Acts supporter, Dr. Demray planned the art exhibit reveal for the opening day of the 2016 Northville Arts & Acts celebration.

When the concept was conceived Dr. Demray and his staff hoped the teeth would be made in the United States. When Dr. Demray’s staff contacted SPI Industries they called SPI Injection Molding plant in South Bend, Indiana. After a short discussion it was determined SPI Blow Molding plant in Coloma, Michigan would be the best approach for the production and molding of the plastic teeth.

SPI Blow Molding understood the teeth would be used to help educate kids on the importance of dental care. The SPI team quickly learned their efforts would also be paramount in the relocation of the Tooth Fairy to Northville, Michigan. This was no ordinary plastic tooth to be used in dental displays or for training for the dental industry!

Fulfillment of the order in time for the Arts & Acts Celebration in Northville set to begin June 17, 2016 was a fun and rewarding experience for the SPI Industry team.

Do you have new product inventions, art installations or even a new twist on an old product that needs attention to detail and experienced engineers to construct? Give SPI Injection or SPI Blow Molding a call today. We’d love to sink our teeth into it.

Read more about how Dr. Demray’s future plans for the teeth to benefit dental care awareness in future blogs.

Get Your Invention To Market: Start With A Strong Prototype

Get Your Invention To Market: Start With A Strong Prototype

Before you begin shopping around your new idea there’s some groundwork you’ll need to take care of first. Having an idea is easy; it’s the steps that come after that are the most difficult. 

A strong prototype will give you many tangible and intangible benefits that will speed up market adoption, and give your invention a chance to thrive. Below we highlight several reasons why you’ll want to start with a strong prototype for your new idea.

1. Having A Tangible Product Gives You Confidence

When you have a spectacular idea for an invention it can be tempting to spend all of your time creating product mockups and refining the initial design. This step is very important, but you’ll never make progress towards your goal if you never create something tangible.

A plastic prototype, even if it is flawed will give you confidence that you’re moving forward with your creation. Once you have the initial prototype you can work with it to truly polish and improve your design.

2. It Allows You To Refine Your Product First

During your first product run-through you’re always going to have kinks to work out. Or, you may need to add or remove certain features. By creating a plastic prototype you’ll be able to refine the design of your product into a workable prototype. You might also start with one type of plastic and molding process, and then decide that another type of plastic will make your product more durable. The range of function and processing methods as well as type of plastics available can be overwhelming to new product inventors.

This allows you to avoid any product mishaps that might occur without proper prototyping. The only way to truly create a plastic product that exceeds your expectations is by starting with an initial prototype and innovating from that point.

3. Can Experiment With Production and Distribution Methods

When taking your design to market chances are you’re going to need to scale. This means you’ll need to have your production and distribution methods ironed out.

By starting with a strong prototype you can smooth out the plastic production process, and any methods of distribution to reach your customers or your suppliers ahead of time.

4. A Strong Protoype Strengthens Your Investment Potential

When you’re approaching potential investors about your product it’s one thing to tell them about it. It’s an entirely different experience altogether when you show them. Graphics, plans, and descriptions can only go so far. By creating a working plastic prototype you enable an investor to truly experience what it’s like to use your product. 

At SPI we can help make inventors dreams a reality.

With our state of the art plastic production and molding facility we can cater to your every need. Our team of engineers has decades of experience producing plastic prototypes across a wide array of fields. If you’re interested in bringing your idea to life, then reach out to our team here, or give us a call at (269) 849-3200.

BPA-Free-Molding-Phthalate-Free-and-PVC-Free-Plastic Products

BPA-Free Molding, Phthalate-Free, and PVC-Free Products

BPA-Free-Molding-Phthalate-Free-and-PVC-Free-Products
There are so many choices when it comes to the type of plastic required for the job, and molding process that will best suit the end result. One of the latest and largest trends is the shift towards BPA-Free molding, and Phthalate-Free and PVC-Free products. At SPI Industries we believe it’s important to stay on top of the latest processes and healthy plastics to truly offer our customers the best service possible.

Below we dive into the reasons you may want to consider BPA-Free Molding, and Phthalate-Free, PVC-Free products for your next product mold.

Why Choose BPA-Free Molding?

Chances are you’ve seen a product labeled “BPA free” when you’ve gone to the store to buy a water bottle, or any type of food container. Studies have shown that BPA bottles have been known to leech BPA into the bottles when exposed to extreme temperatures. With the increase in studies that have shown the potential health risks of BPA, more consumers are now looking for a BPA-free option.

This is where BPA-Free Molding comes into play. This style of molding process will ensure your products are free from BPA. Although, the FDA hasn’t officially labeled BPA as being harmful for consumer use, a lot of companies are already switching their plastic products to BPA-free. Especially, if they produce children’s goods, or food related containers.

Plastic products produced using BPA-Free molding will be free of PVC, phthalate, and BPA.

Best Uses For This Style Of Mold And Plastic

Most plastics that are free from these chemicals are commonly found in products that come into human contact, or are used in food processing. For instance, a lot of children’s toys and baby food containers are produced using this style of molding.

A lot of food containers, water bottles, milk jugs, plastic cups, and bath toys are commonly produced using BPA-free molding as well.

When you’re trying to consider whether or not to use BPA-free molding for your next set of plastic products it’s important to think about how your products will be used now and into the future. If your plastic products will come into frequent contact with humans through physical contact, or will be used to house food-related products, then staying ahead of the consumer preference curve could be very beneficial for your business.

SPI’s Experience With This Type Of Plastic

At SPI our focus is on providing our customers with the molding processes and types of plastics they require for their business to succeed. Since conscious consumer trends point towards BPA-Free molding and the resulting plastics as the way of the future, it’s important for forward-thinking companies to be able to add this to their product lines.

Our processing capabilities and years of experience enable us to ensure your plastic mold meets all of your required specifications the first time through. A lot of facilities may have the right equipment, but without years of experience working with different types of molding processes, the results will be less than desirable.

If you’re a business owner who needs a new line of BPA-Free, Phthalate-Free, or PVC free plastic products, get in touch with our team of professionals today.

Blow molded, Rotationally molded, or Injection molded? How to make a Good Duck

Blow molded, Rotationally molded, or Injection molded? How to make a Good Duck

Which came first, designing the mold or designing the rubber duck? In the case of The Good Duck the bigger question was which process, blow molding, rotational molding, or injection molding, will result in the best rubber duck ever?

injection molded novelty items

Following through on a crazy idea, Craig Wolfe premiered Betty Boop Duck in 1997, and his company, CelebriDucks was born. Originally invented in the USA, this American icon had long since been outsourced over seas. CelebriDucks returned the art of rubber duck manufacturing back to the United States.

From NBA players, to Mr T, and KISS’s Gene Simmons, CelebriDucks are collectible rubber ducks fashioned after some of the greatest icons of film, music, athletics, and history. CelebriDucks was voted the top fan give-away by ESPN in sports stadiums all over the country.

Not easily satisfied, inventor and CelebriDucks founder Craig Wolfe, had to take the product to a higher level. His most recent invention, The Good Duck, is known as the safest rubber duck on the planet.

As most parents know, the first thing babies do when they grasp an object is to put it in their mouth. The Good Duck is made of medical and food grade materials that are soft and safe for teething children. FDA approved, PVC, Phthalate, lead and BPA free, The Good Duck is 100% Made in the USA, and it floats!

With all great ideas comes research and development. Knowing he wanted a safe, soft, rubber duck that floated, Wolfe knew BPA free and PVC free was the way to go. Hence, his tour of blow molding and injection molding plants throughout the United States. As he bounced from factory to factory researching processes and materials he noted SPI Blow Molding in Coloma, Michigan was already using a soft material that could work. Safety and softness was key for the cute duck.

SPI Industries won the development of the Good Duck

Wolfe explained the determining factor for choosing SPI Industries and SPI Blow Molding was the expertise of the people compared to other plastic manufacturing facilities in the mid-west.  SPI had the experience with reach and development to support The Good Duck project.

Still, that’s only part of the story. The softness of the material, the product safety, and the desire for ducks of different color took much trial and error. Choosing the correct material, one that would remain very soft and hold design detail into molds is challenging. Fine tuning CAD designs, re-molding, sculpting, testing and refinement of molds was time consuming and expensive.

Should a Good Duck be blow molded, rotationally molded, or injection molded?

The Good Duck design was originally planned to be injection molded. Once Wolfe started working with SPI Industries, owned James Doster, advised him on a different direction. With injection molding the Good Duck would be in two pieces. The two pieces would need to be glued together. SPI engineers explained, “The plastic needed for the injection molding method would be too hard and would require welding.” Because a true rubber duck needs to float, it needed to be hollow. Blow molding it as one piece and sealing in the bottom was the solution.

The next challenge was determining wall thickness. The soft material they wanted to use with the characteristics that make the Good Duck safe and chewable doesn’t flow like normal resins. Getting the wall thickness exact took some time.

“SPI Companies do more than just manufacturer, they’re trail blazers. They’re making a difference in every way they can, creating jobs and producing innovative products with cutting edge technology.”

For the Good Duck to be completely safe, color needed to be molded right in the product. Adding color was a another challenge because colorant adds weight and effects the floating capability. Consistent balance was critical and very intricate. “Not easy technology, but SPI came up with a formula that is top of its grade with an age grading of 0 and up and thus completely safe for ALL ages!” reported Wolfe.

SPI also provided a great supplier for packaging services for The Good Duck. American gift boxes are usually very expensive and drive up price point. SPI staff helped to locate a gift box manufacturer right here in the United States, keeping cost in line and also ensuring The Good Duck is 100% Made in America.

Future plans are in place to expand The Good Duck line because it is so unique. Communities who hold annual duck races as fundraisers can now use American made ducks! The Good Duck may also be employed as a promotional piece with custom embossing or silk screening of logos.

Wolfe says. “What’s good for you and the planet is the right thing to do. The Good Duck should be done and we should be making it in America. We now have a niche as we’re the only ones making them here and The Good Duck cannot be duplicated anywhere. It’s a cute little duck!”

Wolfe insists on getting the best product out there and The Good Duck will come out of the gate very strong with the highest level of product safety. Watch for the blue, yellow, and pink Good Ducks on the shelves of your favorite stores as early as December, 2015. If you just can’t wait, you can pre-order Good Ducks on the website http://CelebriDucks..com, call 415-456-3452 or email info@CelebriDucks.com

Benefits of Creating a Plastic Prototype for Production Molding

Benefits of Creating a Plastic Prototype for Production Molding
When you consider creating a new part that is to be made of plastic and the tooling cost is considerable, it is most desirable to test the functionality of the part prior to actually building the tool. Creating a plastic prototype can help determine if the part will function as designed. Modifications to a tool can not only be costly but degrade its overall performance and longevity.

The CAD Systems of today, such as Solid Works, which is what we use at SPI Blow Molding and SPI Industries provide a great deal of power to make changes to a part quickly as well as draw all related interacting parts to test the stack up interference fit required in a final assembly. Solid Modeling on the computer has replaced the need for some part prototyping of the past. None the less, there are several current approaches to making a prototype of the product that remain relevant today.

Plastic Mold Modeling:

Historically the only approach was to have a model made by a professional model builder.  The prototype may have been constructed of wood, plastic or metal depending on the size and function of the test needed to be performed on the prototype to prove its size and function.  Many parts today still require a fully functioning prototype model to get exact data from which a mold can be built.  It is a small price to pay for a good prototype part to avoid or at least reduce the iterations of design changes often required while designing and developing new parts and new products.

Rapid Prototyping:

Modern technology, such as Plastic Part Printing, has made prototyping not only less expensive but extremely quick to completion.  In today’s fast paced manufacturing arena the quicker a product can move from the sales planning stage to the manufacturing floor the better.  The life span of a consumer product has become incredibly short, thereby increasing, the pressure to develop new products even faster.  An example of how SPI Blow Molding recently used Rapid Prototype Printing to solve a problem for one of our customers, The Best Bins, was the development of a Portion Control Cylinder which was to be retrofitted into a current bulk food container dispensing unit.  Our engineering department drew the new portion control cylinder using Solid Works.  The drawing was then sent to the Rapid Prototype Entity, where it was produced.

The Plastic Printer, working similar to laying down ink, uses heated plastic resin instead of ink.  The printer then makes repeated passes just as it would if printing on a piece of paper, only it continues to make passes laying down a thin film of plastic resin with each pass.  Each pass prints a slightly different geometry, thus changing the shape of the plastic that is being printed. Each pass also moves up slightly preparing for the next pass.  This process is repeated hundreds and hundreds of times, until a completed part has been produced.  The part can be hollow or in nearly any shape, making it a perfect process to prototype parts for both Injection Molding and Blow Molding, which is what we do here at SPI.

Blow molded plastic bin dispenserThe Prototype Portion Control Cylinder was then tested for the amount of product it would allow to move though the dispensing unit on The Best Bins Bulk Food Container.  The amount was not what we wanted.  Four versions of the prototype part later we were all pleased with the outcome. At that point we were ready to build a new tool.

The amount of time and money saved by being able to rapid prototype this part was significant to our customer.  Without this testing capability we would have been forced to rebuild a mold cavity multiple times, which is both expensive and destructive to the integrity of the new tool.

It should be noted this approach is best used to determine size and fit, not strength and toughness.  Material characteristics will be very different in the prototype than in the final molded version.

Pull Ahead Cavities:

Another approach to prototyping is the concept of pulling forward a cavity in a multiple cavity tool.  If the project is for medium to small plastic parts, then it is very common to use a tool in production containing several cavities of the same part.  In this case it is sometimes wise to build one cavity and use that cavity to product prototype parts.  If changes are required, modifications can be made to that cavity only, allowing all subsequent cavities to be constructed to the newly proven geometry; resulting from the testing on the prototype (pull ahead) cavity.  This is also the prototyping choice where many parts are required for testing and the test challenges the strength and toughness characteristics.

Pull-Ahead-Cavity-plastic-liquid-dispenserSPI Industries used this technique in developing a new plastic collar for Monsanto’s 1 gallon Pump n’ Go “Round-Up” dispenser.  The new tool was to be 4 cavities.  SPI used Mold Flow Software to assist with the tool design.  It was then determined a Pull Ahead Cavity was the right way to go so extensive testing could be done before completion of the other three cavities. We did discover additional changes to be made and thus preserved the strength and durability of the final three cavities.

Reap benefits of creating a plastic prototype for production molding. SPI Blow Molding and SPI Industries injection molding specialize in custom solutions and mold design. SPI Blow Molding and SPI Industries injection molding specialize in custom solutions. Bring us your plastic parts and plastic product manufacturing challenges and let us get to work creating solutions.

What is the best type of prototype for your plastic part?

Benefits of creating a plastic prototype for production molding

3d printer plastic prototype a type of prototype for your plastic part

When you are manufacturing a new plastic part that is to be made of plastic you will save time, money, and stress by testing a mold prior to building the tool. Modifications to a tool can be costly and may degrade its overall performance and longevity. Accurate computer aided design (CAD) software reduces the need for prototyping of some parts. Nonetheless, there are many approaches and benefits to creating a prototype of a product. Determining the best type of prototype for your plastic part is your first step.

Choosing the best type of prototype for your plastic part:

Modeling:

Historically the only approach was to have a model made by a professional model builder.  The prototype may have been constructed of wood, plastic or metal depending on the size and function of the test needed to be performed on the prototype to prove its size and function.  Many parts today still require a fully functioning prototype model to get exact data from which a mold can be built.  It is a small price to pay for a good prototype part to avoid or at least reduce the iterations of design changes often required while designing and developing new parts and new products.

Rapid Prototyping:

Modern technology, such as Plastic Part Printing, also known as 3-D printing has made prototyping quick and inexpensive. With each new product’s life span shortening each year there is much more pressure to create new products and get them out on the shelf as soon as possible.

Pull-Ahead Cavities

Another approach to prototyping is the concept of pulling forward a cavity in a multiple cavity tool.  If the project is for medium to small plastic parts, then it is very common to use a tool in production containing several cavities of the same part.  In this case it is sometimes wise to build one cavity and use that cavity to product prototype parts.  If changes are required, modifications can be made to that cavity only, allowing all subsequent cavities to be constructed to the newly proven geometry; resulting from the testing on the prototype (pull ahead) cavity.  This is also the prototyping choice where many parts are required for testing and the test challenges the strength and toughness characteristics.

SPI Industries used this technique in developing a new plastic collar for Monsanto’s 1 gallon Pump n’ Go “Round-Up” dispenser.  The new tool was to be 4 cavities.  SPI used Mold Flow Software to assist with the tool design.  It was then determined a Pull Ahead Cavity was the right way to go so extensive testing could be done before completion of the other three cavities. We did discover additional changes to be made and thus preserved the strength and durability of the final three cavities.

SPI Offers the Most Current Solutions and Prototypes for your Plastic Part

Do you still have questions on which is the best type of prototype for your plastic part? Please give us a call. SPI’s skilled designers and engineers are experienced in the best practices for plastic part molds and the type of prototype for your plastic part that considers your time, budget and best testing for your specific part.

Bookmark this blog for updates on plastic molding technology and plastics manufacturing. Our next blog will cover more information on rapid prototyping or 3-D printing as it is more frequently known. SPI works closely with a local technical college, Ivy Tech for 3-D printing molds. The Engineering and Design Technology students develop 3-D models for SPI customer review. Read more to determine if a 3-D model will be the best type of prototype for your plastic part.

How To Make A Plastic Mold For Plastic Products and Parts

make a plastic Injection mold for plastic logistic loadbars

Injection molded plastic logistic load bars

Most people within the plastics industry are familiar with creating a mold for plastic products. Or, at least have a general understanding of the process that goes into it. However, some general confusion still exists with product designers, engineers, and other professionals about the ins and outs of the process. There are a number of methods to make a plastic mold for products that will be used for manufacturing multiple quantities of products. Each method will take different amounts of financial investment and time. The steps below will get you moving in the right direction to create your very own plastic mold.

1. Determine Quantity

What’s the quantity of plastic products you’ll be producing? The number of parts and custom plastic pieces you need will determine the type of molding you use, and the manufacturer you work with.

Most manufacturers require that your entire build be at least 100,000 parts or greater. If this number is too high then you may have to shop around until you find the right manufacturer who is willing to do the job for you. Contact SPI Blow Molding or SPI Industries today to discuss quantities, larger plastic blow molded pieces or plastic injection molded pieces can be produced at lower quantities and still be cost effective.

2. Your Budget

What will your budget be for this plastic mold? Your budget for your project should include the design and creation of your mold, as well as future modifications.

Your budget can also influence the method of plastic molding you use, as some are cheaper than others. Also, the more complex your overall design, the more expensive the process is going to be.

3. Overall Size and Design

The type of plastic molding your project will require will be determined by the size and design of your product. You can also adapt your design to use a specific plastic molding process. For instance, when using injection molding you’ll generally have to have a smaller design. While, blow molding is usually used to create products, such as, containers, tubes and bottles.

4. Project Materials

Your project design will influence the materials and types of plastics that need to be used. Sometimes, designs will have a specific material that needs to be used for the product to function, while other times the materials can be more flexible.

Make sure you speak with your manufacturer to ensure you’re using the right material for the job.

Plastic Molding Methods Available

There are a variety of plastic molding methods, which can be used based upon your unique project specifications.

make-a-plastic-mold-blow-molded-bellows

Blow molded plastic bellows

The most commonly used methods to make a plastic mold are:

  • Injection molding
  • Blow molding
  • Compression molding
  • Gas Assist Molding
  • Film Insert Molding
  • Rotational Molding
  • Thermoforming

By going through the process above you’ll have every specification you require to build the perfect plastic mold for your product. This isn’t a process you’ll want to rush, as a simple design flaw can have you starting the entire process again from scratch.

If you’re ready to make a plastic mold or product, or have a question about the process, contact SPI today. No question or project is too challenging for our team! We can help to guide first time product inventors through the plastic molding process, or implement a unique solution for a product redesign that your are considering.

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