Product & Material Engineering

At Molded Dimensions, the Engineering discipline extends from the president to the manufacturing technicians who handle the parts on a daily basis. Each new project is assigned a Project Engineer who focuses on product design for part manufacturability, process engineering for efficient product flow, and lean manufacturing for cost efficiency.

One of our greatest benefits is that our Material Engineering team includes a on-site, degreed chemist. To date, this team has developed over 800 custom rubber and Pentathane formulations - including many compounds that are FDA, 3A, and NSF compliant. Our clients agree that our overall engineering approach to each part results in efficient and effective product designs and process flow.

Tool Design & Contruction

Our in house tool design abilities guarantee a better tool design. Proper tool design is the key to ensuring a better quality part and an optimal manufacturing process. These are both important for long term success. We utilize our in-house tool room to construct both rapid prototype molds and production molds as well as for regularly scheduled mold maintenance. In addition to our in-house tooling capability, we support long term relationships with local tool vendors to construct production molds. Our Engineering staff is both capable and skilled in CAD/CAM software.

Quality Review

The Quality Inspection lab at Molded Dimensions is an exceptionally well-equipped facility, but our facility is only a minor player in the overall quality process. As part of the quality review process, quality becomes a part of the project right from the start. Our Engineering and Sales team completes a formal design review when the project is initiated. This is often followed up by cross-departmental new part FMEAs. As a standard practice, ISIRs are provided to our customers with the first article shipment. Of course, our QA Inspector provides complete PPAPs when requested. In addition to our focus on quality during the first article process, each operator involved in the flow of the product is trained to inspect for quality during his or her operation for each and every production release. Our operators are our most effective inspectors. Weekly continuous improvement meetings involving production, engineering and quality are held to improve our process and reduce the cost of scrap. From the start of a new project through regular manufacturing production releases, our entire quality process is set up to ensure the highest quality.

Metal Preparation

An outstanding feature of Molded Dimension's manufacturing capabilities is our expertise in working with bonded parts. In fact, approximately 50% of the customer parts we manufacture have inserts molded into the part. Various insert examples are stampings, screw machine parts, weldments, and even plastics. The key to a robust bond is part design, mold design, and a controlled metal prep process. This process assures bonding through thorough part cleaning and the skilled application of the proper adhesives. The end result is a bond strength that exceeds the strength of the elastomer.

Urethane Molding

Urethane is used in many cases where one, or several, of its outstanding physical properties are needed. Over time MDI has developed unique urethane formulations that we call Pentathane. Our Pentathane formulations cover a variety of durometers, materials, and colors. Hardnesses range from 20 duro shore A to 80 duro shore D. Included in Molded Dimensions' capabilities with Pentathane is the ability to cast precision mechanical goods and urethane bonded parts. Our casting stations can accommodate a wide range of sizes - from ¼" to 10'. Part geometry and tolerance dictate whether a part is manufactured as compression or open cast, machine cast or batch cast. Overall Molded Dimensions capabilities and flexibility, ensure quality urethane parts and delivery to meet each customer's unique requirements.

Rubber Molding

At Molded Dimensions, we pride ourselves in knowing that we can mold short run orders of 2-10 pieces and accommodate larger orders of 1,000,000 pieces annual. We process a wide variety of thermoset elastomers including: silicone, nitrile, EPDM, neoprene, natural, fluorocarbon, SBR, hydrin, millable gum, and butyl. Most of our masterbatch formulas are customized on-site in our milling and perform department as needed for the specific application. A mix of production capabilities including injection, ram injection, transfer and compression molding equipment supports our flexibility. Our menu of past parts includes the simplest grommet to a very difficult molded hose, to a tightly toleranced, precision molded diaphragm. Every client's part requirements are unique, but we feel that we can draw upon and utilize our vast molding experience to make each and every part successful.

Cryogenic Deflashing

If your part requires efficient, cost effective precision removal of flash, Molded Dimensions is ready. Our cryogenic deflashing department, using belt or barrel deflashing machines can efficiently, and accurately remove flash to RMA specifications. Both types of elastomers, rubber and polyurethane, are excellent candidates for this type of deflashing.

Secondary Operations

If your project requires secondary operations to make it more complete and ready for the next step in your operation, Molded Dimensions is equipped. We have the ability to precision machine both rubber and urethane parts. In addition to CNC machining, we are equipped to perform die cutting, slitting, roller grinding, and even precision lip seal cutting. If you require special packaging, we are ready to provide custom bagging, boxing, or labeling. These secondary operations performed by Molded Dimensions will add to the efficient flow of your product and lower your overall costs. Don't forget to consider it as part of what Molded Dimensions can do for you.