Custom Injection Molding2018-10-10T09:20:05+00:00

Custom Injection Molding

For 70+ years Crescent Industries, has been providing the most comprehensive solutions in custom injection molding to a wide range of industries and product applications. With our tonnage range of 35 tons to 385 tons and also offering vertical injection molding capabilities, we have strategically invested to provide our customers with solutions to their supply chain issues.

  • Scientific Injection Molding & SPC

  • Kitting, Value Add, Robotics

  • Engineering Design & Development

  • In-House Tool Room

  • ISO:13485, FDA, FFL & ITAR Registered

  • Swiss-Screw Machining

various Custom Molding Markets

Whether it’s a simple product design or a complex assembly using our internal robotics and hand-assembly, we have the capabilities to fit your requirements and your supply chain expectations.

custom-injection-molding

The Scientific Approach

Utilizing our Scientific Injection Molding Principles, SPC and state-of-the-art Injection Molding Machines, our focus is to provide our customers with a robust process to produce the highest level of quality for our components and devices. This begins in the early stages in our Design For Manufacturability (DFM), through our qualification and Decoupled Molding process and optimized using our in-process inspection criteria with high-end measurement equipment.

Industries
Served

  • Medical

  • Pharmaceutical

  • Military & Defense

  • Dental

  • Aerospace

  • Industrial

  • Electronics & Electrical

  • Safety

Serving Medical

Part Design Guidelines

The “Injection Molded Part Design Guidelines” will review items to consider when designing your next plastic component like:

  • Maintaining uniform wall thickness to minimize sinking, warping and improve mold fill.
  • Using generous radius at all corners to avoid sharp corners that increase stress concentration which can lead to part failure.
  • Incorporating sufficient draft angles for easy removal of the part from the mold.
  • Using ribs or gussets to improve part stiffness.
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Mold Design Guidelines

Crescent Industries’ mold design engineers look at the aspects of the part that are important for injection molding.  Through adherence to these design principles and best practices at the beginning of the design process will ultimately lead to better overall quality of parts during manufacturing. These “Mold Design Guidelines” will evaluate items like the follow:

  • Gate Designs / Runner Designs
  • Cooling / Venting
  • Actions
  • Mold Filling
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70+ years providing extensive capabilities…

  • Scientific Injection Molding

  • 3D Printing (Additive Manufacturing)

  • Mold Flow and DFM Analysis

  • Kitting, Assembly & Value Add

  • Swiss-Screw Machining

  • In-house Tooling Capabilities

  • Product & Tooling Design

  • Quality Control

  • Product Development

Sampling of our Molding…

Increased Efficiency With Robotics

Automation and robotics are heavily-integrated throughout our injection molding processes and post-molding operations by separating runners from parts, feed and unload injection molding presses, assemble components, sort and package parts, and more. The utilization of this automation gives our customers an advantage by increased throughput and overall time & cost-savings.

Our continued investments into technology has given us the ability to offer additional services. We understand the ultimate goal is cost-savings for our customers’ so we have positioned ourselves as a full-cycle manufacturing partner through enhanced processes and advanced technology.

Collaborative Robotics

Custom Molding Markets

We utilize Baxter, Sawyer and Universal robots to perform highly specific actions with an extremely high degree of accuracy. Our in-house dedicated automation team focuses on programming our robots to achieve increase throughput and cost savings.

End-of-Arm Tooling

OEM/Industrial Industries

We offer a variety of options that are available to industrial robots and automation customized to match the product being handled and can perform a variety of manufacturing tasks.  These task require use of vacuum cups, grippers, nippers, sprue pickers and sensors.

Automated Work Cells

Serving Medical

We utilize cellular manufacturing to perform a variety of multi-task functions within a given work space. This minimizes the hands-on involvement in the overall project and are designed by our in-house automation team working in conjunction with outsourced partners as needed.

Secondary
Operations

  • Device Assembly

  • Product Packaging

  • CNC Machining

  • Laser Engraving

  • Pad Printing

  • Ultra-Sonic Welding

  • EMI or RFI Shielding

  • Heat-Staking Inserts

  • Solvent or UV Bonding

  • Ultra-Sonic Cleaning

  • Cap-Lining

  • Annealing

  • Vacuum/Pressure Testing

  • Sterilization

  • Silk Screening

Engineering Expertise

With our continued investments into engineering resources, our team has the expertise and technical knowledge to assist with your products across various stages and complexity. We love to get involved in the earliest stages of product development to make sure that our customers have the plastic engineering expertise avoiding any costly hiccups in the development process. We work directly with our customers engineering teams providing guidance on the manufacturability of parts ready to be custom injection molded or to create a mold design with the proper actions, gate locations, temperature control and venting.

By utilizing Sigma Soft mold fill simulation software we complete a 3D simulation of how the mold fills, packs and cools during the injection molding process is generated as part of our DFM analysis process. Therefore, problems or concerns can be solved before the parts or mold are even produced.

Pharmaceutical
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70+ Years of Manufacturing Solutions

Through Engineering, Experience & Excellence…

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Advantages of our QRM Approach

In-House Tooling Capabilities

We specialize in building new tooling along with comprehensive maintenance, repairs, and revisions of existing tools. Our journeymen mold builders produce injection molds that provide cavity-to-cavity consistency and repeatability by utilizing high-speed CNC mills, die-sink EDM, and wire-sink EDM. Our capabilities extend from single cavity open and close tools to complex 96 cavity tools with multiple actions, always following the SPI 101-103 mold classifications.

Our cost-saving solutions for new tooling projects provides a competitive advantage over suppliers that don’t have in-house tooling capabilities.

  • MUD (Master Unit Die): The choice when a “dedicated or stand alone” mold base is not required. The part, runner and gate geometry are cut into standardized inserts that fit into the frame.

  • Hot Runner System: An assembly of heated components used to inject molten plastic into the cavities of the mold

  • Unscrewing Molds: Used when there is a requirement for male or female threads on a plastic component

  • Action Molds: Includes mechanical action incorporated into the design when a hole, slot, undercut or thread is needed that is not perpendicular to the parting line

  • Two Plate Molds: Provides one parting line and the mold splits into two halves; the sprue, runners, gates and cavities are all on the same side

  • Three Plate Molds: These molds will have two parting lines and are used because of their flexibility in gating location

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Insert
Molding

Insert Molding reduces assembly and labor costs, reduces the size and weight of the part, improves component reliability and delivers improved part strength and structure with enhanced design flexibility by incorporating metal and plastics or multiple combinations of materials and components into a single part.  The process makes use of engineering plastics for improved wear resistance, tensile strength and weight reduction as well as using metallic materials for strength and conductivity.

Applications

Inserts can be molded into a diverse range of critical plastic components. These components can be used in housings, instruments, knobs and electrical components. Which can be utilized in the medical, defense, aerospace, electronics/electrical, industrial and consumer markets.

  • Magnets

  • Screws

  • Studs

  • Contacts

  • Spring Contacts

  • Surface Mount Pads

  • Rivets

  • Threaded-Fasteners

  • Clips

  • Pins

  • Bushings

  • Tubes

Supply-Chain

Our ERP system (IQMS) gives us the ability to provide a customer portal capability which reports in real-time. This gives our customers the ability to view the status of their project at any given time. Customers may place orders, view product availability, check on order status and shipping status, view production information plus run customer specific reports.

Offering KANBAN shipping of stocked inventory and Just-In-Time Delivery from blanket orders to delivering your parts as you need them which is all tracked and managed through our ERP system. We have our own delivery trucks, so we offer a no charge for regular scheduled deliveries within a 100 mile radius.

Project Management

To be your committed manufacturing solution, our team can support every aspect of your custom injection molding and business needs. Our Project Management Office (PMO) manages new mold builds, tool transfers, and new projects. They examine the entire scope of your project, timeline & cost management, material selection, design & development and overall integration with your engineering team.

Essentially, you receive a dedicated team of professionals that collaborates, communicates, coordinates and executes. In addition, we have dedicated R&D injection molding machines to aid in initial sampling and validation to accelerate all phases of your project and transition into full production.

Crescent’s Core Capabilities

Molding

Safety

Molding presses ranging from 35 tons – 385 tons with state of the art equipment and robotic integration for:
Medical Injection Molding
Military & Defense Industry
Custom Injection Molding

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Tooling

OEM/Industrial Industries

Single-cavity to complex 96 multi-cavity tools including documented tool transfer process & scheduled preventative maintenance programs. Our In-House capabilities offer complete solutions.

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Value-Added

Defense/Military

Offering a comprehensive range of skilled labor, collaborative robots and automation. Our kitting and value add services lead the industry with solutions for complex assembly projects.

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Engineering

Electrical/Electronics

Single-source solutions from concept into production with 3d Printing (Additive Manufacturing), tool & part design and dedicated R&D Machinery. Our Project Management team collaborates, coordinates, communicates, and executes.

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Manufacturing Needs?

Entire Engineering Solutions!
Crescent’s capabilities
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Blog & News

  • Is it time for a new Medical Injection Molding supplier? Here’s some tips.
    There are endless reasons as to why an OEM will choose to change their medial injection molding supplier or think to change. The main 6 categories that we often see as the culprit are:
  • Obtaining an accurate proposal for injection molded tooling and components
    The Request for Quote (RFQ) and competitive bidding process is an important one for the plastic injection molding industry. Not only does it help OEMs secure the best overall value and quality results for their production needs, but it also rewards high-performing contract manufacturers with business, providing competitive pressure for the innovation, specialization, and continuous […]
  • How to Evaluate Total Cost of Ownership
    One of the biggest issues in the injection molding industry—for both molders and customers—is evaluating the total cost of ownership of a product or project. Though there are several things OEMs can do to make their RFQ’s more accurately match their molding needs, customers still need to carefully and comprehensively analyze the quotes received from […]

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