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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.

SPI Industries Offers Vertically Integrated Manufacturing

Ready-to-use Quality Parts on Time,

at a Fair Price 

Benefits of Vertically Integrated ManufacturingSPI has adopted vertically integrated manufacturing solutions to ensure our customers receive high value and on-time delivery. By managing the entire supply chain of each plastic part, our customers enjoy cost savings, maximized efficiency and value along with consistency throughout their product line.

Vertically integrated manufacturing includes multiple phases of plastic parts development.

Managing each step of the development process allows SPI to deliver a full-service solution to customers. Integrating the entire process from concept to delivery helps maintain the integrity of each product and allows for delivery of ready-to-use quality parts on time, at a fair price.

Examples of SPI Industries vertical integration capabilities:

cnc machine for plastic part manufacturingProduct Design Support and Development
• CAD design support

Engineering
• Dye / Mold engineering

Plastic Mold Making
• Mold Testing

Material Sourcing

Plastic Mold Production
• Blow molding
• Injection molding
• ThermoformingCMM - Coordinate measuring machine (photo is of CMM Mitutoyo BN715) to identify different types of measurements

Assembly

Packaging / Pack Out

Labeling / Branding

Product Package and Insert Design Support

Distribution

Delivery

Warehousing

Sales and Marketing

SPI works with OEM’s of all sizes. From small start-up companies to large corporations, we consistently hear how challenging it is to get a product to market.

When your plastic part or plastic product has to be ready, you don’t have time to research multiple manufacturing blow molders, injection molders or thermoforming — let alone attempt to integrate all of their schedules. Vertical integration manufacturing from SPI Industries streamlines each phase while reducing costs, delays, and errors.

Examples of how Vertically integrated manufacturing practices benefit customers of SPI Industries:

A new customer came to SPI Industries with a new product that required blow molding, injection molding, and assembly. With SPI’s vertical integration the customer was able to achieve cost benefits with design support, tooling, manufacturing, and shipping. The cost and time benefit allowed the new customer to increase market share by offering a new product to the market with shorter lead time and a lower cost.

A current blow molding customer was having a delivery issue with their current thermoforming supplier. SPI Industries thru vertical integration was able to mold the components at one plant and CNC trim the components at another. This integration of manufacturing allowed SPI to help their customer meet current demands and avoid the loss of orders.

Benefits of Vertically Integrated Manufacturing and Supply Chain Management:

Cost Savings – cutting costs also lowers the price of each product
Sustainability – Less impact on the environment (reduced travel, packaging, etc.)
Increased communication – work with the same project lead instead of multiple managers in different locations
Maximized Value – Keeping Manufacturing in the United States and Great Lakes Region – Supporting local economy helps your community and also increases sustainability
More consistency – using the same molds, staff, and equipment assures each part is the same overtime
Increased flexibility and Customization – Each process affects the next. When a change is considered all project heads or engineers can be brought up to speed together and concerns can be addresses
Reliability – when one company is handling each step of your project they have a buy into the success of your product (they have a lot to lose too!)
Maximized Efficiency – Increased communication, consistent points of contact, No concerns of delayed shipping

Manufacturing demands increase daily and we are all tasked with finding ways to increase efficiency and maximize value. SPI Industries wants to remove the headache and unforeseen costs from your product development. Give us a call today. We will review your current supply chain and offer suggestions so you can have ready-to-use quality parts on time, at a fair price

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.
SPI Full service manufacturing boxes in warehouse with forklift great lakes region

Full Service Manufacturing of Plastic Parts

SPI Full service manufacturing boxes in warehouse with forklift great lakes region

SPI Injection Molding and SPI Blow Molding offer full service manufacturing of plastic components and finished goods. As a full service manufacturing source in the Great Lakes region, SPI can handle all aspects of manufacturing for your product that contains injection or blow molded plastic parts. From design and tooling, to quality control and assembly, to packing and fulfillment, SPI supports your success by delivering quality parts on time, at a fair price.

From concept to completion

In this competitive market, companies seek every opportunity for cost savings. Maintaining high levels of quality while meeting increased demands for faster turn offers a competitive edge. Working with one experienced plastic molding company instead of working with multiple companies at different stages of the manufacturing process ensures consistency and accuracy for your plastic parts. Selecting full service manufacturing from SPI Industries helps you breathe easy.

Benefits of Full Service Manufacturing of Plastic Parts

Shorter production times

Keeping all phases of the plastic part manufacturing process with one company, reduces production time. Once production begins, each step in the process is set and scheduled. With full service manufacturing, all communication and coordination is streamlined into a proven system and managed by a team of professionals. Each part moves smoothly from tooling to delivery.

Reduced plastic part manufacturing costs

At our full service manufacturing facilities, engineers, designers, and manufacturers work together on each project. The close proximity of the departments allows them to communicate quickly and efficiently. If there are adjustments needed throughout the manufacturing phase they will be identified and addressed at each step. This level of quality control can’t be obtained when each phase of production is outsourced to different companies.

Streamline communication

Working with one company decreases errors caused by inefficient communication. We’ve all encountered issues when changes have not been explained accurately or in a timely fashion. Whether in business, or in our personal lives, limiting the amount of people involved in a process reduces the chance for miscommunication. With full service manufacturing you contact one team. There is no need to schedule meetings with multiple teams or determine logistics for communicating across different time zones.

Time is money.

Each step in the manufacturing process that can be eliminated saves time and money. Because a full-service manufacturing provider is accountable for all aspects of a project, often a higher level of personalized service will result. The buck stops with the full service manufacturing provider. There is no blaming other vendors. Ensuring all processes are correct in the very beginning helps projects move smoothly through each stage. Additional cost savings are returned through discounted rates offered by many full-service manufacturers that niche companies do not offer.

Keeping everything under one roof also eliminates the need to allocate additional funds for packaging and transportation between manufacturing facilities. Staff training, estimating, billing, reports, and correspondence is streamlined when all phases of a product are completed by one company.

Would you like to learn more about how SPI Industries could serve as your full service manufacturing source in the Great Lakes region?  SPI Industries’ processing technologies include blow molded and injection molded ready-to-use plastic parts. Give us a call today or complete the inquiry form to connect with an SPI product specialist. Certified to ISO 9001:2015 standards and compliant for food-grade parts, SPI will design and build your mold and deliver ready-to-use quality parts on time, at a fair price.

Accurate Estimate for Plastic Molded Parts

How To Get an Accurate Estimate for Plastic Molded Parts

Accurate Estimate for Plastic Molded Parts

Are you a developer, designer or inventor of products that requires blow molded or injection molded plastic parts? Do you think you are ready to bring your new idea to market? Are you looking for a price quote for blow molding or injection molding for your new product?

SPI is regularly contacted by developers, designers and inventors, who’s products are at varying stages of development. More sophisticated and experienced customers may have 3D CAD files or prototype molds built before calling us. Some customers may have 2D drawings or a homemade prototype mocked up. While, still others bring only sketches or concepts. We have examples of each maturing into successful product launches.

While the appearance of the product or the visible parts may be well thought out, the function, material and plastic molded part design requires a great deal of exploration. Below, we discuss some of the design questions we consider to deliver Quality Parts at a Fair Price.

We have specific questions that need answers before SPI can provide an accurate estimate on part pricing. We look at ways to help design for ease of manufacture at both the part design as well as the tool design. Producing a clear and thorough estimate for plastic molded parts design and development requires a great deal of communication and expertise.

Before you are ready to manufacture your idea, these questions are important to consider:

What is the end use of your product?

  • Will the part be exposed to chemicals?
    If a product is going to be exposed to bleach, or ammonia or other chemicals, there are specific resins that we will recommend to used that will ensure the integrity of the plastic part over time and use.
  • Will your product hold food or beverages for human consumption?
    There are specific guidelines required for food safe storage products. Because of the stringent guidelines, not all injection molding or blow molding companies offer food safe plastic solutions.
  • Will your part be exposed to extreme temperatures or other environmental conditions?
    These considerations will allow your molder to offer recommendations of resins and special additives that may be used to allow your part to function under extreme conditions.

Specific Design Elements will determine best processing technology for Plastic Molded Parts

  • What are the dimensions of your plastic molded parts?
    The size and annual demand of your part will dictate which plastic molding process is required. SPI can help you determine the best processing technology for your product. Typically, small, complex parts such as handles for tools or pens are ideal for injection molding. Hollow objects such as bottle and beverage containers are best suited for blow molding. Where does your product fit? We can help.
  • How complex is your part? Will your part need to be flexible?
    Is your part a simple rectangle with one notch that will connect with another part? Does your part have multiple levels, notches, clips or bellows? Does your part start large and get progressively smaller? Do any elements of your part need to move or be removable? Is a portion hard, while another component pliable such as a clip that must be squeezed into a hole to later expand? The complexity of the design will dictate the type of material, time needed for the mold development and tooling.

What materials are best for your plastic molded part design?

  • Which polymers or resins are best for your product?
    If you are not familiar with the many types of plastic materials on the market, a qualified plastic molder can help you make the best selection. Once a molding engineer knows the end use of your product, the size, quantity, and processing technology, they should be able to offer options for the best material selection for your plastic molded parts.

As you can discern from the many questions posed above, there are many variables that will determine the best solution to manufacture, assemble and deliver your product. The manufacturing company you choose should be a partner in the success of your product. Give SPI Blow Molding or SPI Injection Molding a call, we look forward to partnering with you to help launch your new product. We will support your success by delivering Quality Parts, On Time at a Fair Price.

Plastic Product Manufacturing Michigan and Indiana

plastic-product-manufacturing-michigan-and-indiana

SPI Industries has been a leader in the Midwest custom molding and plastic product manufacturing scene since the 1950s. Our beginnings revolved around injection molding and high quality tool design and building. Over time we have expanded our capabilities to include custom blow molding, product assembly and customer fulfillment in South west Michigan. We are equipped to handle the entire manufacturing process from start to finish. It begins by working closely with customers to define the part specifications of our clients, based on the product requirements. We pride ourselves in delivering our customers Quality Parts.

Our experience in a wide range of plastic product manufacturing processes, helps reduce time and money spent generating designs and test prototypes. We can help facilitate the design and manufacturing of your product from concept to delivery. We pride ourselves in delivering our customers Quality Parts, On Time.

SPI has a long history of being a “Go To” custom blow molder in southern Michigan and custom injection molder in northern Indiana. Our experience as custom molders, has given us a broad knowledge base with many resins and processes that most other blow molders and injection molders wouldn’t even consider. This allows us to succeed at projects where others have failed. SPI can also let you know when there may be a better approach that we simply do not have the capability to provide. We pride ourselves on delivering our custom molding customers Quality Parts, On Time, At a Fair Price.

Why Choose Injection Molding?

Injection molding is the most commonly used type of plastic product manufacturing in use today.  The process can be used to manufacture items that consist of over 18,000 different types of plastic materials, such as thermoplastics and some types of thermosets and elastomers.

The injection molding process has existed since 1872; the first products manufactured by this process were billiard balls made by John and Isaiah Hyatt. However, injection molding can be used to manufacture almost any solid or open-ended object, from hair combs to the dashboards of cars.  The plastic injection molding process consists of injecting a molten plastic material into a metal mold and letting it cool and dry.  Designing molds for injection molding requires a lot of expertise; a mold must be designed so that the part will be of uniform thickness and allow it to be easily ejected from the mold.  SPI Industries is experienced in designing molds for injection molding. We will sample the mold and make minor adjustments until they are just right for manufacturing before we begin mass producing your products.

Often creating prototype parts will help in both part design as well as tool design. Having a prototype part for more complicated designs will generally help to reduce the amount of adjustments during the sampling process.

Why Choose Blow Molding?

In contrast to injection molding, blow molding is the process used for making hollow plastic parts.  It is also required when making items that vary in thickness in different parts of the object, such as gas tanks.  Blow Molding is commonly used for higher volume parts that are currently being roto-molded, due to a faster cycle time when compared to roto-molding. However, the nature of blow molding usually has longer cycle times and more processing variation than injection molding.

The SPI Industries Difference

Here are some reasons why SPI Industries should be your first choice for plastic molding manufacturing in the Great Lakes region

  • We can handle all steps of the design and manufacturing process, which will save you time and money.
  • We are equipped for both injection molding and blow molding.
  • We have decades of experience and keep up with the latest technological advances in plastic product manufacturing.
  • We are familiar with the requirements for plastic products in many different industries.
  • We can do small runs of products, large runs, or anything in between.
  • Because of the amount and variety of equipment we have in house, we can help bring your ideas to fruition in a relatively short time frame.

Quality Parts. On Time. At a Fair Price.

Benefits of Thermoplastic Elastomers for Injection Molded Goods

Benefits of Thermoplastic Elastomers

Also referred to as thermoplastic rubber, thermoplastic elastomers (TPE) have become increasingly popular for a wide spectrum of products and applications. Below we cover some of the benefits of Thermoplastic Elastomers and how they have changed the look and feel of many products on the market today.

Consider household and personal care items you have purchased recently. Hand held goods for personal and industrial use such as tools, utensils and toys, that are manufactured with TPEs have soft, smooth handles that make gripping much more comfortable.

From toothbrushes, to spatulas, to screwdrivers and new rubber ducks, many new products are manufactured with this long lasting plastic and durable rubber combination. The tactile feel of thermoplastic elastomers is just one of the popular benefits to end users.

The speed and the ease of processing for plastic injection molding and plastic blow molding also makes it a popular choice for manufacturers and molders. Thermoplastic elastomers can be used in countless extrusion and injection molded applications. When compared to traditional resins, thermoplastic elastomers can be molded in shorter cycles to allow for quick turn round of molded goods.

TPE is also a solution for products that need to perform in a variety of temperatures including plastic products that will be exposed to the outdoors.

ADVANTAGES and BENEFITS OF THERMOPLASTIC ELASTOMERS INCLUDE:

  • Processing ease and speed
  • Design flexibility
  • Lower fabrication and production costs
  • Lower energy consumption
  • Resistance to solvent and abrasion
  • Resistance to weathering
  • Improved product performance
  • Shorter cycle time
  • Lower part costs per finished piece
  • Broader range in product density
  • Product consistency
  • Environmentally Friendly – recyclable scrap
  • Resistance to heat and cold
  • Can be injection molded, blow molded and thermoformed

These benefits of TPEs are just some of the reasons SPI Blow Molding and SPI Injection Molding recommend thermoplastic elastomers for a wide range of products and part design applications customers bring to us. Molding custom plastic parts with top grade TPEs that can save time and money as well as stand up to seasonal climate change is important to our customers.

Do you have a product or part that could benefit by incorporating thermoplastic elastomers? Give us a call today. SPI Injection Molding and SPI Blow Molding experts will consult with you and your team to determine if thermoplastic elastomers could save you time and money on your next part design project.

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

Where to Get Custom Injection Molded Plastics in Michigan

Custom Injection Molded Plastics in Michigan
When you’re planning to purchase or design custom injection molded plastics in Michigan, Indiana and the surrounding states there are many factors to consider. Because there are multiple avenues to take it’s important that you consider your options before moving forward.

Below we’re going to showcase how you can choose the best custom injection molded plastics in Michigan company for your needs. There are a lot of variables to consider, so make sure you choose wisely.

Multiple Industry Availability

The industry you work in will help to determine the style of plastic parts you require. Every injection molding facility won’t be able to deliver the level of parts you need to complete your project.

Everything from food containers, children’s toys, outdoor recreation products, to home supplies, to manufacturing goods, and more. Each of these types of goods will require a different kind of finished product, and some facilities will be better than others. For that reason it’s important to understand the specs surrounding your product before you place an order with a plastic injection molding facility.

For example, do you require thin walls or thick walls? Is your product complex or easy to produce? Do you need a high or low quantity?

These questions and more will help to guide the selection of your facility.

Ability to Produce Custom Parts

Can the plastic molding facility provide custom parts?

If you’re looking for an injection molding facility, then chances are you’re going to need a custom part. Some facilities only produce a set of standard parts, and don’t have the required machinery to cater to custom part creation.

Services To Help Base Your Decision

Below you’ll find a list of the most common distinguishing factors that will help you choose the right facility for your custom injection molded plastic parts.

  1. Short-Term vs. Long-Term Runs – Do you require a continuous supply of parts for the long-term, or do you only need parts for a short period of time? Some facilities require you place an order of over 2,000 units, while others are more flexible. When choosing your Custom Injection Molded Plastics in Indiana or Michigan production facility, make sure you find one that provides the correct parts on the timeline you need.
  2. Prototypes – The process of prototyping (link to older blog post) allows you to test different versions of your unit, before moving forward with the final step in production. There are multiple styles of prototyping available. If you don’t have a completely perfect model of the plastic piece you’re going to need produced, then you can greatly benefit from a facility that enables you to prototype first.
  3. Craftsmanship Due Care – What level of plastic parts do you need produced? In some cases you can get away with having lower quality plastic parts, but other times you must ensure every mold is created perfectly. The level of care and craftsmanship you require will help to determine which facility you choose.
  4. Thin Wall, High Tech Parts – The injection molding equipment and process they use will create different types of parts. If you require thin walled and high tech parts, you’ll need to work with a facility that offers that style of part. Once again, choose a facility that has a background in producing the style of part you require.
  5. Secondary Operations – What about when the parts are complete? Do you need a team to assemble, store and ship your parts, or will you do this yourself?

These secondary options can be costly, but also necessary depending upon the type of business you run. Some facilities cater to shipping, storage, and assembly, but others do not.

If you have any questions regarding where you can get your plastic molded parts, then get in contact with SPI today. We love help our customers across the Michigan area get the plastic parts they need.

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