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May 13, 2021by Chase Bodor

Plastic manufacturing is a popular subject that appears across every industry. From food processing to automotive components, plastic is a staple of the products we use. It’s in our packaging, our transportation, our clothes…it’s everywhere! To meet the high demand for plastic, manufacturers leverage different types of processing capabilities. This includes blow molding, compression, extrusion, rotational, 3D printing, and injection molding. Each one of these methods is capable of producing a specific plastic application. For example, blow molding is best for making plastic bottles, and extrusion is best for tubes. Our service, injection molding, is perfect for mass-producing plastic components.

 

We’ll discuss these different plastic manufacturing methods in depth throughout this segment. Follow along, or skip to one of the methods of your choice.

 

What is Injection Molding?

 

Plastic injection molding is a popular method of making a variety of plastic parts. This process involves melting thermoplastic material through an injection molding machine. First, plastic resin enters the machine via the hopper and enters the barrel. The barrel contains a reciprocating screw, which mixes and melts the plastic. Then, the press injects the molten plastic into a single or multi-cavity mold. The mold clamps shut during injection and open at the end of the cycle. Finally, the cooled part falls from the press and is handled by a machine or an operator.

 

This is an oversimplified explanation of course, but the capabilities of molding are easy to illustrate. For example, this cycle happens (in most cases) under a minute and sometimes even under 20 seconds. Pair that speed with a multi-cavity mold and you can make thousands of parts a day. Ultimately, this means you can take advantage and scale production quickly.

 

To wrap up this section (because I could go on) injection molding is fast, scalable, but also repeatable and versatile. The results of injection molding are consistent from run to run, which means you can expect a certain level of quality. And it is versatile because you can make complex 3D shapes. Of course, you have to optimize your design for manufacturability and assembly for it to be moldable. But, if that is taken care of then the possibilities are limitless. 

 

Ultimately, injection molding is best for high-volume production. Whether that application is a medical device, automotive component, or bottle caps; you can produce lightweight, strong plastic parts.

 

What is Rotational Molding?

 

Rotomolding is similar in the way that it utilizes a mold to force the plastic to take the desired shape. Except in rotational molding, the polymer is a fine powder that fills the mold.  The mold is placed on a rotating arm that operates by moving on a 3-dimensional axis, which helps fill the mold. The mold, while in rotation, enters into an oven that produces heat between 400 and 500 degrees Fahrenheit. The oven encloses the mold for the necessary duration, then moves to a cooling phase. The mold cools under specific conditions dictated by the material and size of the mold.

 

Rotational molding is a low-pressure manufacturing process. This means that the tooling requirements aren’t as much as other methods, which reduces the cost. For instance, a thin-walled aluminum mold is much less expensive than heat-treated stainless steel used in injection molding. Additionally, there is an opportunity to ‘foam’ rotomolded parts. This means that you can add insulation, floatation, and other capabilities to your product.

 

Rotational molding is considered a versatile process when it comes to plastic manufacturing. But Rotomolded parts are typically bigger, less precise units that are machined for functionality. So if you want a large plastic unit, like a play structure or a large drum container, rotational molding may be right for you.

 

What is Blow Molding?

Water bottles in a blow molding plant

 

As explained in the introduction, blow molding is great for making plastic bottles. But how does it work? Well, it’s actually like glass blowing but with plastic. You start with a small plastic parison- a rounded mass formed by heating and rolling- and blow gas (air) through it to inflate. Essentially, the small plastic mass inflates according to the shape and size of the mold. Once it cools, the inflated part ejects from the mold.

 

Blow molding is great for manufacturing one-piece, hollow plastic objects. Like soda bottles! It is also useful for thin-walled applications like plastic storage containers. Like injection molding, blow molding produces high volumes because of its quick cycles. Additionally, there are many thermoplastic materials that are compatible with this process. This creates plenty of opportunities to create specialized products.

 

What is Compression Molding?

 

Compression molding is another popular molding method used by automotive part makers. The process is like injection molding, except the mold closes around the plastic during compression. For illustration, the plastic ‘charge is set on the bottom half of the mold. Then, when the press starts the top half smushes the charge into the cavity. The plastic fills the cavity and seeps out into overflow grooves. This is like the runner and gate in injection molding.

 

Another key difference is that compression molding uses thermoset polymers. This means that after molding, the resulting component must ‘cure’ in a kiln-like oven. Through curing, the component settles into and holds its finished shape.

 

There are 4 main steps to compression molding:

  1. A two-part metallic tool matching the exact dimensions of the object is produced, installed, and heated to the requirements of the plastic.
  2. The plastic composite is pre-formed to the shape of the tool.
  3. Under pressure, the pre-formed object is inserted in the hot mold and compressed. This pressure ranges anywhere between 800 psi and 2000 psi depending on the thickness of the part.
  4. The part is removed from the tool and any flash on the edge is trimmed off.

The main benefit of compression molding is the ability to use advanced composite materials. These materials include thermosetting resins, glass-reinforced plastics, fiberglass, and other strong materials. With these materials, you can create a wide range of parts for a variety of applications. Also, with compression molding, you can create simple and somewhat complex geometric shapes. To summarize, compression molding is versatile enough for many low and medium-volume production projects.

 

What is Extrusion Molding?

The initial process of extrusion molding resembles that of injection molding. The extrusion press uses a screw to melt and push plastic resin through the die. A die, unlike a mold, is a hollow form that shapes the plastic as the screw pushes it through. In other words, the die dictates the specific shape and thickness of the manufactured part. The extruded part is then conveyed into a cooling chamber- a water bath or spray booth. At the end of the cycle, a saw or blade cuts the long extruded material in sections of the desired length. 

 

One key feature of extrusion molding is its continuous process. For example, the extrusion press continuously feeds plastic through the die. This creates a long beam or tube of molded plastic that stays intact until it is cut or wound into a spool. If you haven’t picked up on it yet, extrusion molding is great for long, hollow applications. For example, tubes, straws, pipes, and wires are also extruded applications. Also, channel sections are a popular extruded product as well.

 

What is Additive Manufacturing (3D Printing)

 

Additive manufacturing is better known as 3D printing. And it is all the rage in the 21st century. 3D printing uses CAD software and 3D object scanners to program hardware (such as a printer) to make an object. In other words, the digital software recreates an object digitally; which tells the hardware how to physically make it in layers. The 3D printer then produces super-fine layers of material in precise geometric patterns. Layer by layer, the printer deposits material until the final product takes form. This can take minutes, hours, or days depending on the object. But, additive manufacturing is still considered an easier way to develop and test prototype products.

 

While the technology is advancing, additive manufacturing is still behind in volume capabilities. But, as hinted above, you can skip the wait and test prototypes quicker than other molding processes. For example, with injection molding, you would have to spend thousands of dollars to produce a prototype tool. Not only is that expensive, but the lead times on a tool can set your schedule back. Plus, if for any reason the product is redesigned then that is another costly headache. With 3D printing, you can develop and test prototypes in weeks, not months.

 

Wrap Up

Now you know the basics of plastic manufacturing! There are a lot more details once you go further into one of these processes. Don’t be discouraged though! There are experts in each of these fields that can help you and understand your challenges. If you’re looking for an injection molder then give us a call!


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May 7, 2021by Chase Bodor

Injection molding is a common process for making plastic products in large volumes. Most people that are familiar with the subject know its capabilities.

Those same people also know another aspect of injection molding: the cost of building a mold.

The capital investment with building a new tool is a challenge for buyers and engineers. This investment checks out in the tens of thousands or even hundreds of thousands of dollars. A sum like this causes friction for launching new products to market, where the product has yet to be tested. Additionally, a project that is still testing the market won’t have a clear ROI forecast.  Because of this, many teams are hesitant to invest in a tool without proof in the pudding.

Luckily, injection molders provide options for teams in different stages of their project. One of these options is to select a class of tools that matches your needs. For example, there are three types of tooling: prototype, bridge, and production. Each type of tooling has its benefits and disadvantages. But, each type will offer results at a reasonable price. Let’s jump into these tooling options further.

 

Prototype Tooling

 

Defining ‘prototype tool’

A prototype tool, also known as a Class 5 tool, is a low-volume run tool made for products that are in the development and testing stage. This class of tooling is great for testing a design’s functionality while staying flexible with design changes. Because of this, prototype tooling is a great starting place for rolling out new to market products.

 

Prototype tooling costs

The upfront investment in tooling is the biggest barrier to injection molding. Production-ready tooling is often too much for projects that are new and unproven.  In comparison, prototype tooling is by far the lowest-cost option.  Because of this, many companies choose to build a prototype tool first and then test their design. By doing this, companies will identify issues early and correct them on production-level tools. This will help cut costs at the earliest value stages of the project.

 

Types of Steel Used in Prototype Tooling

One of the key differences between tooling types is the kind of steel used in the mold build. When building the mold, a toolmaker can choose from a few different steel types. Each of those options will affect how long the tool lasts, how well it performs, how expensive it is, and what features the tool can use. Additionally, every type of steel has its own core properties. For a prototype tool, the mold base is made of low to mild-grade steel or aluminum.

 

Key Features of a Prototype Tool

Prototype tooling is a no-frill, but cost-effective way to get parts made and onto the market. Because of their simple configurations, a prototype tool uses cut-in-steel cores and cavities. This means that the toolmaker will cut the cavity/ core into the mold block itself instead of making interchangeable cavities. Additionally, class 5 tools will often opt out of expensive features: like complex cooling channels, runner systems, slides, and other features found on production tooling.

 

Takeaways from Prototype Tooling

+ Cost-effective

+ Great performance for the price

+ Standard textures and polishes

+ Great for testing features/ fit for applications

+ Flexible designs

+ Great for testing market demand and project ROI

– Low volume 

– A short lifespan (>500shots)

– Minimal features

– Soft steel (easy to damage)

– Not weldable

 

Bridge Tooling

Bridge tooling is the intermediate step between prototype and production tooling. As the name suggests, this type of tool is a stopgap for products that have succeeded in their early stages. As a result, these products are ready for higher volume production. And with high volumes comes the need to upgrade your tooling. 

However, bridge tooling is limited when compared to production tooling. For example, a bridge tool is not equipped with advanced features- like complex cooling channels. But, by choosing not to have these features you can cut significant costs. For this reason, bridge tooling is great for dialing in the process, calculating ROI on the project, and testing the market. 

When should you use bridge tooling? And when is it appropriate to use full-production tooling? The answer to this depends on several factors. For instance, we look at the product’s application, the expected volumes, the material used, and more. 

Mold Base and Tool Life

The steel used in a bridge tool is dependent on how many lifetime shots you expect to get out of the tool. For a Class 4 tool, the base can be made out of mild steel material. This will get you up to 100,000 shots/cycles. For a Class 3 tool, you will have to spend more to get hardened steel (minimum of 165 BNH). However, with this tool, you can expect to get 5 times the amount of shots (500,000).

Material Hardness (Resin Choice):

Material choice is an important factor in deciding what grade steel to use. For a bridge tool, a harder resin will wear the tool down faster. This will affect the life expectancy of the tool. Additionally, if the tool closes on a rigid plastic part, it could damage the mold. These damages aren’t dramatic, but the cost of maintenance and potential downtime increases.

Application- How it’s used:

The product’s environment and function influence the volume and material. First, if the parts are high in demand and replaced often, then you can expect high volume production. Second, if the parts are often exposed to harsh environments- chemicals, heat, etc… then you will need rigid material. With the combination of rigid material and high volume, it is best to consider hardened steel.

 

Production Tooling

Think you’re ready for production tooling? Great! There are many reasons to build a production-ready tool. One of the main reasons: dependability. A hardened steel tool is reliable and can make hundreds of thousands of parts. Thus, these tools make great ‘flagship products’- your main product offering. 

Mold Base and Tool Life

Class 1 and Class 2 tooling are your best options for high-volume production runs. All Class 2 molding services (cavities and cores) are made of 280 BHN hardened stainless steel. Additionally, this steel is heat-treated to a minimum of 48 Rockwell “C”. This hardness allows the tool to last up to 1 MILLION cycles.

A Class 1 tool will get you into the multi-million cycle mark for extreme volume projects. This type of tool also has a minimum hardness of 280 BHN but is heat-treated to 48 Rockwell “C”.

Summary of choosing the right tool for your needs.

Ultimately, a high-end car is better than a low-end car, but there are reasons to hold off on the big price tag. The same applies to an injection molding tool. A production-capable tool may have all the bells and whistles. Yet, the cost of hardened steel and complex fixtures may surpass the needs of your project. 

Ultimately, the type of tool you need depends on where you’re at in your project’s lifecycle. If you’re launching into a brand new project or one you haven’t tested the market for, build a bridge tool. 

If the design you have may go through many revisions before it goes on the market, build a prototype tool.

If you have the next best product on the market, and you’re selling quantities of 500k or more, splurge on a production tool.


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April 27, 2021by Chase Bodor

Since its invention in the ’60s, the copy and paste function has been a vital time-saving business tool.  With this tool, businesses eliminated repetitive work that was already done before. In other words, they didn’t need to reinvent the wheel again and again. What better time-saving shortcut is there for a business? Well…

What if I told you that there is another version of copy and paste. This version actually doesn’t make life any easier for your business, or yourself. In fact, this version of copy and paste steals the very idea or product that has taken you months, even years to build. And unlike on a computer, there is no undoing it. All your hard work is copied and pasted in an instant for someone else’s profit.

This is the danger of IP theft in outsourced manufacturing.

As we go further into this topic, we will discuss how IP theft happens in the big picture. First, we will talk about the different agents involved in stealing business IP. This is also known as industrial espionage. Then we will cover the ecosystem of outsourced manufacturing. White label manufacturing plays a big role in IP theft and is worth studying in this context. Following this section, we will look at some basic principles of protecting your company’s IP. Finally, we will talk about why trustworthy relationships go a long way towards protecting your IP. This includes a conversation between myself and a product design firm.

 

What is IP theft

According to the FBI (who I believe is credible for this topic), IP theft is stealing peoples’ and/or companies’ ideas, inventions, and creative expressions. These are intellectual properties- which include trade secrets, proprietary products, and media engagements. 

There are four main types of IP:

  1. Trade secrets
  2. Trademarks
  3. Copyrights
  4. Patents

IP theft is becoming a more prevalent issue as digital technologies and Internet file-sharing networks integrate into major business operations. For example, sensitive information transferred over the web is a prime target for internet hackers. We will discuss the different scenarios in which IP theft occurs later in this segment.

In general, IP theft happens more where trademark laws are less defined and harder to enforce. For example, overseas companies are major offenders of  US-based IP theft. In fact, Chinese theft of American IP costs the US between $225 billion and $600 billion annually. These numbers are from an investigation led by the United States Trade Representative. Additionally, those numbers match with a 2017 report from the Commission on the Theft of American Intellectual Property. As you can see, IP theft can result in serious economic damage and can stun business growth.

 

How does Ip theft occur?

There are many opportunities for thieves to steal intellectual properties. For instance, internal and external data mining can reveal lots of sensitive information. In other words, protecting your IP is not as simple as locking your front door and buying an SSL certificate for your website. We will discuss some best practices for protecting your IP later on. For now, let’s jump into who engages in industrial espionage and how they extract information.

 

The common IP thief

The internal agent: Someone who steals/ reveals their company’s IP from the inside. This person is someone who joins a company with the sole intent of spying to gain information. In other words, they were working for someone else all along. These internal agents can release sensitive data about your company. They can also hinder its competitive edge by taking proprietary tools. 

A disgruntled employee is another common IP perpetrator. This person takes revenge on his or her company for their perceived wrongdoing. They can also talk their peers into sabotaging the company from the inside if they’re persuasive enough. As a result, you may have many internal seeds working to compromise the company.

An expert moving within an industry is also a threat to intellectual property theft. Although less common due to non-compete agreements; someone can move companies within an industry and take some of the IP with them. Although this isn’t illegal in some cases, there are moral implications with this behavior.

And finally, there is always a potential for inside information to accidentally leak out. This happens when someone from inside the company sends information across unsecured channels. Or to the wrong recipient entirely. 

External Agents: Someone who infiltrates your company’s data through hacking or other forms of unsolicited collection. People who work in an office setting will come across many attempts to steal information. The most known methods: phishing, hacking, etc, are disguised well to imitate a familiar transaction. In fact, these information heists mimic high-profile people within a company. They will ask the receiver to send sensitive information with urgency. If successful, these attempts are devastating. And the recovery from such an event can take years if they recover at all. This is why having protected channels to send information is so important.

 

Common IP theft scenarios

Let us review some common scenarios where IP theft can occur:

  • Internal Agents
  • Leveraging privileged access 
  • Spys/ investigators
  • Disgruntled and persuasive employees 
  • Accidental information leak
  • External Agents
  • Hacking/ phishing
  • Surveillance
  • Data mining (including paper trails)
  • Security breach

 

How does IP theft affect me?

For those who are still reading and think “oh this will never happen to me or my business” think again. Many small and medium-sized businesses are targets of scammers, hackers, and IP perpetrators. And your company’s books aren’t the only thing they’re after. They are after anything they can pull from you and use for their own gain. If your company owns IP or holds customers’ IP, think what can happen if those “secrets” are in the hands of someone who can re-engineer it for themselves. 

Let’s look at this from the lens of a manufacturer– a business that manufactures goods for sale either for themselves or for other companies.

 

How is outsourced manufacturing involved?

Manufacturing plays a significant role in IP theft. As hinted earlier, a manufacturer holds an entire portfolio of IPs.  And holding these different properties gives the manufacturer a ton of responsibility. This responsibility isn’t always held close with a moral compass either. You will find some manufacturers steal ideas, products, and technologies from their clientele. They then reintroduce those products into the market under a different brand. 

In this next section, we will discuss what role outsourced manufacturing plays in IP theft. Also, we will discuss two manufacturing methods: White Label and Contract Manufacturing. While the two share some similarities, they both pose some risk to a company’s IP.  Furthermore, we will explore what a Copycat Manufacturer is and its role in IP theft. In the end, we will transition into some helpful ways to protect your IP.

 

White Label Manufacturing vs Contract Manufacturing

What is ‘white label’ manufacturing

White label manufacturing is a popular option for outsourcing manufacturing. In this process, a retailer or brand hires a manufacturer that produces a product they want to sell. The retailer purchases the product and slaps its label onto it. The idea behind this is a well-recognized label can make it look like it produces its own product line. When in reality they buy their product at wholesale prices from a manufacturer. To summarize, a white label manufacturer makes its own products but makes them available for sale to retailers. At the same time, the manufacturer can use its own sales channels to sell that product to other retailers or consumers.

 

what are the differences between white label and contract manufacturing?

A contract manufacturer is different from white label manufacturers in a few ways. For example, companies hire contract manufacturers to produce parts, components, or final products. The hiring firm first establishes the design specifications that the manufacturer must follow. Then the manufacturer orders the necessary consumables and runs its processes. Based on the agreed terms, the manufacturer produces a set number of parts over a specific timeframe. Once the manufacturer fulfills the order, the parts get shipped back to the hiring firm. At no point does the manufacturer sell these parts under their own, or any other label. In fact, both parties enter into a contractual agreement that protects their interests. This agreement involves sharing intellectual properties, designs, processes, and more. To learn more click the links here on contract manufacturing and NDA’s.

If you didn’t pick up on it, I will tell you the big difference between the two types. The big difference between contract manufacturers and white label manufacturers are:

  1. White label manufacturers can make and sell products as their own.
  2. Contract manufacturers make parts exclusively for another business.

Although this doesn’t seem like a huge revelation, there are a ton of implications. For one, the white label manufacturer can take a “new” product to market with little effort. 

Remember what I said about the moral compass?  Well… 

There are examples of overseas manufacturers that take someone else’s product to market. To put it in different terms, these manufacturers rip off an idea and sell it as their own. Whether IP is explicitly stolen, or they create off-brand products meant to mimic a large national brand; this process breeds something called Copycat Manufacturing.

 

Copycat manufacturers

A copycat manufacturer takes a product or idea and spins it to make it look like their own.  They even will clearly rip off the existing product label to trick consumers into buying their product.  For example, a copycat will keep the same branding as well-recognized products. This is so consumers will think highly of the product and choose it based on the discount price.

A great example here shows the many knockoff variations of Dr.Pepper.

Copycats are a huge problem in the manufacturing space. These manufacturers not only copy well-performing products, but they hurt the value of the existing products. 

Not only that, there is a huge negative impact on the US and global economy. The International Chamber of Commerce estimates that counterfeit products and stolen IP will negate a total of 4.2 trillion US dollars from the global economy by 2022.

To bring the point back around, not all white-label manufacturers steal IP and create their own product offerings. But, the ones that do are playing a huge role in this micro-chasm of stolen IP-turned rip-off products. This is the risk you run by not protecting your intellectual properties. And also by working with an unvetted manufacturing partner.

Now you understand the risks of unprotected IP. Next, let’s look at some ways you can stay vigilant and protect your business.

 

Managing the Risks of Outsourced Manufacturing

IP Security Screen

Is my IP at risk if I outsource manufacturing?

The short answer: yes.

But the risk of getting duped by a manufacturer you know and trust is quite low. The arrangement between producers and sellers is a time-tested affair that has worked for most businesses. The key to this relationship has been, and always will be, trust. 

While working with a circle of manufacturers you trust is important, you should still protect your IP. If someone steals your business’s IP, it is very hard to find and prosecute the thieves involved. And there is no telling how long it will take to recover your IP.

In this next section, we will cover some helpful tips for keeping your IP safe.

 

How do I protect my business from IP theft?

To keep your business IP safe follow these six principles suggested by Awake Security:

  • Identify Your IP
    • Identify exactly what information you want to protect and from whom to protect it. Through this exercise, you can align your leadership group with your security goals.
  • Locate Your IP
    • Without locating where your IP sits (IT systems, file cabinet, you name it) you won’t know how to protect it. Because we’re looking at this in the context of manufacturing, you will want to audit your third-party systems as well. This includes ERP systems, product catalogs, technology stacks, and more.
  • Conduct a Risk and Cost-Benefit Analysis
    • Do you know how much it would cost you if you were to lose your high-profile assets? Do you have a priority list when it comes to IP? If not, this exercise will help you identify which assets will cause the most harm if they were lost. Also, this will help you identify where to invest in security systems to prevent a large loss.
  • Educate Employees
    • Help the people in your organization understand what IP is at risk of exposure. By educating your team they can better protect and prevent IP breaches from happening.
  • Identify Protection Gaps
    • There are many opportunities for a thief to attack your business. Auditing your systems by thinking from an attacker’s point of view is an excellent way to identify any gaps in your current system. Once you’ve identified some areas for improvement put on your thinking cap! Start with small adjustments and aim for continuous improvements. Also, consider making investments in your security to boost your protection.

 

What to Consider for Your Manufacturing Partnership

Choosing the right partner is time-consuming and has an incredible impact on your company’s success. But, not all manufacturers are created equal. That’s why vetting your potential partner is an essential step before doing business.

Before you put pen to paper- consider looking into your potential partner using these criteria:

  • Location:
    • The location of your supplier is a huge consideration when you factor in time-to-delivery and responsiveness. Working with an offshore manufacturer might cost less upfront. However, I’m biased to working with domestic partners for several reasons. For one, you have more visibility into your supply chain. Second, you can communicate in your own language. This is key when situations arise that can be problematic. Choose the location of your next supplier wisely.
  • Capabilities and Experience:
    • Would you choose the world’s best Sous Chef to cater for your company party? Maybe, but they probably aren’t the best choice. Choose a supplier who has an ample amount of experience working in your field. This will make the process seamless and your communication clear cut. They’ve worked with companies like yours before so they know the challenges you face.
  • Check references:
    • This and the item above go hand-in-hand. Check references with other companies who are also supplied by the same manufacturer. Most of the time, these companies will have a scorecard, approved supplier list, or at least some nice words to say.
  • Labor Practices:
    • Again, working domestically helps mitigate some best labor practice issues. Evaluating the working environment of your supplier will give you some insight into the culture of the company. Also, this will help you understand how they treat people inside and outside the company. Red flags? This is a sign that you might run into issues down the road.

To wrap this up, we would love to start a conversation about a potential partnership. If you’re looking for an experienced injection molder based in the US, then look no further than here! With over 40 years of experience, we’ve helped many companies with their projects. Plus, we keep a tight ship over here. So you can trust us with your intellectual properties. Give us a call and see how we can address your molding challenges!


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April 26, 2021by Chase Bodor1

Looking for contract manufacturing?

When it comes to manufacturing there are two ways of doing it:

  1. Roll up your sleeves and do it yourself.
  2. Find someone who knows how to do it well and have them do it for you.

The first option is empowering. You have complete control over the process, quality, and the ultimate outcome. In the same way, you can run around your house fixing any problems that arise with some elbow grease and a tool belt. You would have complete control to make repairs how you want.

Except manufacturing isn’t all that simple. And instead of elbow grease, you will need an army of elbow greasers with an immense level of expertise. Not only that, but you will also need to buy a house (manufacturing plant) and very expensive machinery to get the work done. 

This is a big undertaking. Especially for businesses that focus on scaling their business through sales and marketing. That is why working with a contract manufacturer is SO valuable! A contract manufacturer gives you access to valuable resources at a fraction of the cost.

After reading this article you will understand what a contract manufacturer is and what a partnership includes. Finally, we’ll show you how to select one that fits your needs.

 

What is Contract Manufacturing?

Contract manufacturing is the process of outsourcing your production requirements to a facility that is better equipped to fulfill them.  In other words, a manufacturer is hired to make products or do other labor for the hiring company. In most cases, the manufacturer produces a set amount of products within a given period of time. 

 

How does contract manufacturing work?

 First, the contract manufacturer approves all the job requirements. Then it will perform the job based on the contractual agreement.  This includes approving the design, material, processes, shipping requirements, and more.

The contract manufacturer does not own any intellectual properties that it is producing. No, the hiring company owns most, if not all the IP. This includes drawings, processes, work instructions, packaging, and more. In fact, many contract manufacturers make products EXACTLY to their customers’ specifications. These are build-to-print services. There are also build-to-spec services, but that won’t be covered in this writing.

The contractual agreement can extend for a long period of time. This gives the hiring company the ability to order products on demand from the manufacturer. To receive more products, the company places an order and specifies a date they need it delivered by. The contract manufacturer then pulls together the necessary materials and starts producing parts. Once good products are available, quality will inspect the parts and send samples. Once approved, production can continue until the order is complete. This process repeats until the agreement is either completed or terminated.

Learn more about the resources you need to pull together before starting production.

 

What types of contract manufacturers exist?

There are many niches that leverage the services of a contract manufacturer.  As a rule of thumb, most contract manufacturers are exporters or converters of raw materials, machinists, or assemblers. For example, we are a plastic injection molding company. We convert raw plastic material to produce plastic components. These are used in applications for medical devices, automotive, and mission-critical operations. Our specialty is in plastic materials and processing. And we also offer machining, assembly, and other services as secondary ops.

For a better overview, check out this list of contract manufacturing examples:

  • Raw materials processor (rubber, plastic, steel)
  • Die casting/ mold building
  • Machining (CNC, milling, grinding)
  • Stamping
  • Foundry model (for semiconductors and electronics)

 

Why is contract manufacturing important?

Contract manufacturing is important because it provides the ability to perform full-scale production that would otherwise be impossible without capital-intensive investments. 

Manufacturing requires expertise, a skilled labor force, accessible resources, quality control, supply-chain management, and more. Even then manufacturers themselves can’t produce everything they need. With a contract manufacturer, a company has access to the necessary resources that would be otherwise near impossible to get. With access to these resources, they can focus their strengths on their customers’ needs.

 

What Work does Contract Manufacturing Include?

First, you need to pinpoint what work you’re hiring for. For example, if you’re hiring a sub-component manufacturer then the scope of work will be different than an assembler. But, if you hire a comprehensive manufacturer you will have more options to choose from.

Generally, there are a few important assets included in working with contract manufacturers. These assets are the main selling points for why you need a manufacturing partner:

Facility and Equipment

The facility and equipment cost is a huge factor in outsourcing decisions. With contract manufacturing, you are essentially leasing the space and equipment owned by them. This is less expensive and causes much fewer headaches.

Labor

We are talking about two kinds of labor forces: skilled and unskilled labor.

Unskilled labor– This labor force includes machine operators, assemblers, heavy-lifters, and others. They are often underappreciated, but super valuable members of the team. These people handle raw materials, finished goods, and make sure your products are taken care of. Ultimately these workers aren’t expensive but are an essential part of the puzzle.

Skilled labor– Skilled labor refers to those who deploy knowledge, expertise, or a rare and valuable skill in their work. This includes engineers, processors, machinists, material experts, and more. These workers are fewer in numbers but contribute more value. Additionally, these experts are more difficult to find the more specialized they are. This makes it harder to bring their expertise in-house for your own processes. But, they work for manufacturers in their respective vertices. Which makes them accessible as part of the partnership.

Sub-components

While some companies are makers of one-piece products, others make multi-part assemblies. These multiple parts, or sub-components, are a part of a large device as a whole. Many companies will contract a manufacturer to produce these sub-components so that they don’t have to produce every part in-house. They will even ask to produce multiple parts, assemble them, and ship them as a finished good. 

Full-Scale Production

This allows businesses to contract out many production activities down the supply chain. For instance, in the automotive industry, there are three-tiers of suppliers:

Original Equipment Manufacturer (OEM) – An OEM is the label company that is often designing, marketing, and selling the car. These manufacturers make some original parts but engage more in ordering parts and assembling the final car. They order parts from their 3-tier suppliers.

Tier 1– Tier 1 suppliers are the direct suppliers to the OEM. This tier of companies works with multiple car manufacturers. But, they have some exclusivity with one or two OEMs. 

Tier 2– Tier 2 suppliers also make car parts in this example. Yet, these companies usually don’t sell directly to OEMs. Instead, Tier 2 suppliers sell to Tier 1 who then distributes that along their channels. Another difference is that Tier 2 suppliers are not industry-specific. In other words, while some do make automotive parts, they can also serve other industries. Tier 2 suppliers are experts in their niches and have a broader capacity for serving different markets.

Tier 3– Tier 3 suppliers are suppliers of raw materials, like plastic and metal. Each of the tiers above is dependent on this one. Because of this, Tier 3 has a great responsibility within the manufacturing supply chain.

To summarize this section, contract manufacturing can be distributed amongst the three theirs. In fact, this allows for greater supply-chain visibility and flexibility.

 

When Should I Start Considering Contract Manufacturing?

If you’re reading this right now and salivating at the idea of contract manufacturing, then you’re ready. If you’re not sure yet, then that’s fine too! Ultimately, you must look internally at your own capabilities to determine if it’s right for your business.

In our experience, companies who fit the bill for contract manufacturing:

  • Have limited resources (equipment, labor, process, expertise)
  • Are already stretched thin (limited bandwidth)
  • Want to focus on their current strengths
  • Have a complex supply-chain
  • Have variable demand for their products

 

How do I choose a contract manufacturer?

There are many factors that go into choosing a contract manufacturer. 

The most important- find one that you trust will have your back and can do the job right. 

You can find hints about how a manufacturer conducts business with some thorough research. Most contract manufacturers have a way of conveying their capabilities for your specific needs. Others will have references, work history, or verified qualifications that prove they can meet those needs.

Here are the top 5 things we recommend taking a look at when comparing contract manufacturers:

  1. Certifications:

Most manufacturers that are well established have ISO-certified quality management systems (QMS). If not, then the company would need further investigation or should be removed from your list. ISO certification from a third party demonstrates the manufacturer’s commitment to quality. Plus, some certifications cover industry-specific requirements that need to be met. This should give you more confidence in their ability and results.

2. Examples/ history of working in your industry

The point of contract manufacturing is to relieve your business of extra work, not add more. Thus, a manufacturer with experience in your industry can help you solve problems and speak your language. Without this quality, you will spend more time asking questions than solving problems. Look for one that has experience within your industry, or has similar capabilities.

3. Excellent Referrals

Manufacturing is a business that thrives on referrals. If someone had a great experience working with a contract manufacturer, then they’ll tell you. 

If not, they will also tell you.

Most companies keep supplier scorecards that show performance over time for that manufacturer. Other sources include reviews, verified partner badges, group affiliations, and similar third-party verifications.

4. Good labor practices

This one is harder to test but is a crucial piece of the puzzle. You will find that some manufacturers aren’t transparent about their labor. This could be a sign of trouble. A poor work environment affects the quality of their work, aka your product. And if they don’t treat workers well, how do you think they treat customers? I’ll let that go unanswered.

5. Supply-chain network

As I’ve stated a few times, the supply chain is crucial. You want a partner with a steady network of suppliers who can activate when needed. Long lead times, late deliveries, defect parts are all things you want to avoid right? These hiccups cost your business money, so avoid them with a well-tied supply chain partner.

 

What Are the Benefits of Contract Manufacturing?

When working with contract manufacturers, you are reaping a ton of benefits. But, those benefits don’t come without some risks as well. Here we will break down some positives and negatives when outsourcing your manufacturing.

 

Advantages of contract manufacturing:

  • Cost savings
  • Scalable production
  • Flexible manufacturing solutions
  • Increased Quality
  • Repeatable outcomes

 

Disadvantages of contract manufacturing:

NONE… Just kidding, there are a few:

  • Stolen intellectual properties (IP)
  • Bad fit for service
  • Unreliable and potential for poor customer service
  • Less control over the outcomes
  • Disagreements over terms, partnerships, etc…

 

Final Notes

In summary, contract manufacturing is a great service that can help your business scale. For businesses that lack manufacturing resources, I would highly recommend finding a contract manufacturer to work with. Finally, if you have any questions about the process or you would like to learn more about our service then give us a call!



March 31, 2021by Chase Bodor
Now that’s a Big Ass Fan!
 
We’re happy to announce the installation of our new fans ahead of the summer months. If you have ever been to Southern California in the summer then you’ll understand why we’re so excited.
 
We started this project in the winter knowing we should get a head start on the hot days ahead. Even with temperatures in the mid-80’s the warehouse is beginning to feel stuffy. Could you imagine what it would be like when it’s 110-120 degrees?! And the warehouse is even hotter.
 
There were tons of reasons why we wanted to install fans in our building. In previous years, it was a challenge to keep our staff cool and hydrated. While we did have smaller fans that helped, the environment was still uncomfortable. Not only that, but it is dangerous to work in those conditions- not by anyone’s fault. It was time to do something that would make a big difference.
 
But this year is a different situation altogether. Yes, we expect there to be heatwaves, high temperatures, A/C issues, and everything else you expect in a California summer. What we didn’t expect is the lasting impact that Covid-19 would have on operations. With all the safety measures in place to operate ‘normally’, there had to be more we can do to host a safe workplace.
 
The solution- Big Ass Fans! BAF combined some sort of ion technology, that kills bacteria and viruses, with their big fans. With these fans we could tackle two challenges: We can host a safer and cooler workspace.
 
As we turn these bad boys on and let them run, we’re excited to see the difference they make.


October 31, 2019by Chase Bodor

Plastics Plus Technology had been working with the Inland Empire United Way to help make the community better.   You may remember in our last newsletter that we packed lunches for needy school children in the area.   The United way has another program which supplies students and teachers with many school supplies which may be un-affordable for lower income schools or families. Their facility is equipped with a “store” complete with isles full of pencils, papers, and any other school supplies you can think of.   Students and teachers come buy and pick up supplies at no cost as they need them.

We were looking for ways in which PPT may be able to support this effort and decided that we can donate pencil boxes.  PPT owns several molds that can produce various sizes of plastic boxes.   To keep costs down we manufactured the boxes from regrind scrap material left over from other parts  Normally this material would be sent to a material recycler, however in this case it was given new life as a pencil box for needy children in the area.

The boxes were a success and the united way was very happy to receive the donation.   PPT was happy to have an opportunity to help and to give new life to material that would have otherwise been scrapped.



August 13, 2018by Chase Bodor

Plastics Plus was delighted to welcome Rudy Murillo to the team this summer as an Intern Engineer. Rudy, a local Californian, is pursuing his degree in manufacturing engineering at Arizona State University: Polytechnic Campus in Mesa, AZ. In his education, Rudy worked on various projects that required programming, machining, design, concept development and everything in between. This summer he was able to apply his knowledge and work directly with our project managers in developing automated tools to expand the company’s capabilities. Rudy was able to bring fresh ideas to the table, gain valuable insight into the world of manufacturing and help take Plastics Plus a step forward. He will be returning to Arizona this week to finish school and start his new position. We wish Rudy all the best in his upcoming graduation, his new position, and future endeavors.

As he leaves for Arizona, Rudy was able to give his final reflection on his experience:

 

What was your first exposure to manufacturing/ engineering?

My first exposure to engineering was during my visit to the Naval Academy where engineering (in several disciplines) is the main degree offered by the University. During the week, we observed many examples and acts of science (mainly physics) in the study halls where the Midshipman(students) attended their classes. 

What fascinates you about M&E?

The idea that everything is made, whether it is on a small or large scale; and the method that is used to create a product can determine the overall success of a company. Manufacturing is always changing and evolving so rapidly that the idea of full-scale automation does not seem like a far-fetched concept. To be part of a generation that will be working closely with new technology is exciting, especially to experience the power available to us first-hand thanks to such technology.

 

Pictured: Rudy working hard in the tool room on his project.

 

What was it like working at Plastics Plus? 

My experience at PPT was awesome! Seeing and interacting with some of the various machines was different and insightful on how some operations are run. I was forced to think outside of the box and find possible solutions for abstract movements and processes.

What useful skills have you learned as an intern here?

I worked a lot with SolidWorks, which is crucial because manufacturing involves a lot of modeling and programming. That process is vital to making a viable tool capable of manufacturing quality parts. I also had the opportunity to work hands-on with a milling machine and learned different methods of setting up and making good cuts in aluminum.

What are your goals following graduation? 

The biggest goal I have after graduation is to put myself out of my comfort zone wherever I go. I hope to learn new skills that will follow me for the rest of my life and have opportunities that I would never have before.

Looking back, what are some of the highlights of your experience?

Overall, the internship was a great learning experience and I have learned quite a bit of information because of the mistakes that I made. I definitely know that I underestimated the time to machine the final box for the pressing machine in the hopes that I had enough time to finish it. I will definitely take the lessons and skills that I have learned at PPT and take them with me on my future endeavors wherever they may take me.

 

Thanks for coming aboard with us this summer Rudy, and good luck!



August 6, 2018by Chase Bodor

When it comes to injection molding, the pre-production stage can be challenging to those who are unfamiliar with the part and tool design process. Plastics Plus has decided to create a simple post on the different ins-and-outs of tool design that explains what goes into designing a mold and how your part design is affected. What good tool design does is save time and money by making sure your part comes out of production to the specifications you desired; while exemplifying good quality, strength and usability.

Click Here to Read the Full Article!



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Plastics Plus Technology is a woman-owned, USA contract manufacturer based in sunny Southern California. Our custom injection molding and value-added services can provide you with a one-stop job shop for all your injection molding needs.

ISO 9001:2015, ISO 13485:2016 Certified. FDA Registered. Good Manufacturing Practices (GMPs). WBENC.

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