DPI’s Vast Range of Plastic Injection Molding Capabilities Sets Us Apart
Diversified Plastics is an excellent choice for custom injection molded products.
Our range and size of engineered plastic components that DPI can injection mold is nearly limitless in the industrial sector, with our capabilities for molding machine shot sizes ranging from 19 oz. up to 311 oz.
In-house tool design and mold fabrication allows DPI to be a single source supplier for our customers. “We strive to make doing business with DPI seamless, and having all operations under one roof helps us obtain this goal.”
Injection molded UHMW is our specialty – a process not duplicated by anyone else in the world. DPI continuously provides substantial cost savings to customers when converting high cost machined UHMW components to the molded process.
Just some of the materials we use
- UHMW-PE
- Nylon
- Acetal
- Urethane
- Ultem
- PEEK
- HDPE
- Polypropylene
- Glass, carbon, and oil filled.
Mold It or Machine It?
Understanding the molding process and when to utilize it can lead to big cost savings. Low and high volume machined replacement parts are often great candidates for molding instead. The DPI sales and engineering team members have the experience and expertise to help our customers identify and qualify which plastic parts and components are the best candidates to convert from machining to molding. The process includes analyzing geometry, part function, material, and possible design changes to optimize for the molding process.
Mold and Save!
Investing in an injection mold is a short-term investment when compared against long-term savings. Part testimonials in the diagram are just a few examples of five-year savings versus their machined counterparts.
We’re Committed to Finding the Best Solution
Experience creates trust and for over four decades companies globally have trusted DPI to qualify, analyze, and define the most cost effective method of producing their plastic components. If we succeed, our customers succeed and the result is profitable and sustainable growth for all parties. Our model is to be the only source for all your plastic component needs, and to be an industry leader who adds value through innovative ideas, knowledge, and passion to be the best. Additionally, we offer prototyping to test concepts, processes, and materials.
DPI is a leading plastic molding company. Contact us to learn how our team can advise you on the right molding solutions for your engineered/industrial plastic parts applications. Learn more about the benefits of converting to plastics.
In-House Tooling And Design
For efficient prototyping and production, quality control, and cost savings.
Our in-house engineering capabilities streamline the development of quality, custom parts, and components. To support your unique plastic parts design and production needs, our process includes:
- Complete in-house tooling, molds, and fixtures
- Custom software and programming solutions
- Reverse engineering and analysis
- Rapid prototyping services
- Collaborative on-site meetings
Tool Room
- HAAS VF-2 30”X 20”Y 20”Z
- EDM Sinker
- HAAS VM-3 40”X 26”Y 24”Z
- Small Surface Grinder
- HAAS VF-6 64”X 32”Y 30”Z
- Ejecter Pin Grinder
- Knee Mill
- Horizontal Band Saw
- Manual Lathe 16” X 60”
To accommodate a wide range of parts sizes and designs, our molding machines include:
- 19 oz / 200 ton (2000kN)
- 29 oz / 320 ton (3200kN)
- 59 oz / 380 ton (3800kN)
- 89 oz / 530 ton (5300kN)
- 143 oz / 700 ton (7000kN)
- 155 oz / 674 ton (6000kN)
- 200 oz / 800 ton (8000kN)
- 300 oz / 1200 ton (10000kN)
Frequently Asked Questions
We can work with virtually any injection moldable material. Our work is primarily focused on industrial and high-wear applications, so the materials we use most often include UHMW-PE, nylon, acetal, polypropylene, HDPE, polyurethane, PEEK, Ultem, and glass-, carbon-, and oil-filled compounds. If you have a specific material in mind, we’re happy to discuss whether it’s a good fit for your application.
Our largest press can produce a single-shot part weighing up to approximately 20 pounds of plastic, with footprint dimensions up to around 4′ x 4′. We also run multi-shot processes for complete parts exceeding 30 pounds. Wall thickness is not a limiting factor for us — some of our molded parts have walls up to 4 inches thick.
A few things. We design and build our injection mold tools in-house — something very few U.S. manufacturers do. That gives us better control over cost, quality, and tool longevity, and means our engineering team is deeply involved in every project from the start. We’re also able to mold extremely large and thick-walled parts that fall outside the capability range of most injection molders. And because machining, custom fabrication, and urethane casting all happen under the same roof, we can combine processes to develop solutions that simply couldn’t be made anywhere else.
Yes. We continuously automate to reduce labor and maximize throughput. Our processes incorporate automatic conveyors, sprue pickers, robot arms, cooling systems, grinders, hoppers, feeders, and packaging systems. Many production runs are set up so that machine operators aren’t required once a run is underway.
It’s one of the most efficient manufacturing processes available for plastic parts. Cycle times range from just a few seconds to around four minutes depending on part complexity, and we regularly use multi-cavity tooling to produce multiple parts per cycle. For reference, one of our higher-volume products molds 32 parts per cycle in 78 seconds. No other process can make parts that efficiently.
It varies quite a bit depending on part geometry, the number of cavities needed, and material. We build all of our tools in-house and use standard mold base options when available to help control costs. Simpler tooling can start around $2,500, while more complex tooling can run into the hundreds of thousands of dollars. We provide clear tooling costs upfront as part of any conversion evaluation.
That depends on part geometry and material. For tight-tolerance applications, we use an iterative tooling process, gradually removing material and trialing parts to dial in critical dimensions. We can also apply our in-house CNC machining capabilities to near-net-mold a part and finish-machine any dimensions that require extra precision.
Molded Products Sell Sheet
Injection Molding Line Card
