Davies Molding Blog — Insights on Custom Plastic Molding, Knobs & Handles

Tool transfers are often framed as simple logistics decisions. Move the mold, start production, reduce cost. Done!

Highly regulated sectors such as medical devices or aerospace parts are often associated with specialized manufacturers and strict processes. In actuality, the foundational requirements of these industries are process control, repeatability, documentation, and material traceability. These are not exclusive to regulated markets. They’re the same fundamentals that define best-in-class industrial manufacturing.

Whether engineering a medical device, aerospace assembly, industrial system, or consumer product, bringing a new plastic component to your market requires much more investment that simply selecting a material and commissioning a mold. Successful OEMS understand that the earlier the engineering team engages with their molder, the smoother the entire operation will be from conception to production.

Have you started rethinking your supply chain strategies, including onshoring your plastic molding? Onshoring or bringing production back to the US offers businesses significant advantages, especially in industries like plastic molding. For many companies, this is emerging as a necessary approach going forward.

While handles may not be the first component considered in the designing of a product, it can have a lasting effect on the aesthetics and overall reputation of the product. It is important to choose components that significantly impact how the user feels about a product. One wrong choice can have a lasting effect on the perception of the product, even if the overall product works well. We have all experienced a soft touch handle that starts to shed material with extended use or worse breaks under stress. Handles like this may do the job temporarily but could affect the product reputation over time. With that said, as a product designer there is a constant tension between durability, feel and added cost. Choosing a premium soft touch handle provides the perfect balance of functionality, durability and aesthetic appeal.

Enhancing Molding and Tooling Capabilities

Warrenville, IL – May 10, 2024 The Heico Companies announced that it has completed its acquisition of Versatile Mold and Design, Inc. Headquartered in Rutledge, Georgia, Versatile designs, builds, and maintains high precision molds for both thermoplastic and thermoset materials and provides molding services as well.

In plastic molding, making products that last isn't just a desirable trait—it's essential. Having a component fail on a product, even as small as a knob, can have immeasurable impact on the perceived quality of the product as a whole. Businesses rely on their vendors to create components that will withstand the test of time and ensure reliable performance therefore minimizing the need for costly replacements. A plastic molding company should fully embrace quality before focusing on volume.

In the world of music, every note and detail matter a lot to top musicians. A musician's identity is wrapped up in their sound, gear, and how they present themselves. Choosing the right equipment is crucial in shaping this identity. It may seem simple, like picking a guitar, amp, or pedal, but experienced musicians know there's way more involved in making the perfect sound. The details matter.  One detail that can’t be overlooked is the instrument control knobs. After all, look, feel, durability and reputation play a part in your crafting excellence. Some might argue that any knob will do, but those that know realize this is not even close to accurate. Amid a concert, having a knob that feels just right in your hands is indispensable – it not only ensures a secure grip but also eliminates worries of slippage or breakage, adding a touch of professionalism to your performance by avoiding the pitfalls of a cheap appearance.

Davies Molding is proud to be able to celebrate Manufacturing Day and continue the long tradition of US based manufacturing excellence. Manufacturing day is held the first Friday in October. Manufacturing Day gives us, manufacturers, at Davies, the perfect chance to shine a spotlight on our manufacturing expertise and the incredible skills of our workforce. It's all about inspiring the next generation of skilled workers. We open our doors to showcase the potential of modern manufacturing and foster interest in manufacturing careers.

Why is there a manufacturing day?

Across the country, organizations showed the public what manufacturing really looks like through more than 2,600 open houses and other events in each of the 50 states along with Puerto Rico, according to nist.gov. The hosted events had an estimated 400,000+ students, parents, and community members attending. This community outreach is important as, according to the National Association of Manufacturers, manufacturing accounts for 10.94% of the total output in the states and employs nearly 9% of the workforce. The total manufacturing output for 2019 was $2,345.85 billion which is an increase of $600 billion since 2010. In addition, there was an average of 12,182,000 manufacturing employees in the United States in 2020, according to the National Association of Manufacturers. There continues to be strong demand for local talent to join the manufacturing industry. In fact, according to a study by Deloitte, as many as 2.1 million manufacturing jobs could go unfilled by 2030 due to lack of qualified applicants. During the pandemic-challenged year of 2020, the manufacturing industry lost 578k jobs and at any given point in the last 6 months, nearly 500k jobs have remained open. This is an ideal time to get involved as manufacturing continues to grow and the talent pool is low.

Why does Davies participate in manufacturing day?

With a rich history spanning nine decades, Davies has proudly participated in every National Manufacturing Day thus far, and we are firmly committed to remaining an integral part of this celebration for all the forthcoming Manufacturing Days to come. The plastics and rubber products industry is one of the top 10 manufacturing sectors in the US. Davies Molding stands as a premier player in the plastic products industry, consistently ranking among the biggest and best composite and plastic manufacturers. With this position in the market, there is continuous high demand for our top-notch products leading to a high demand for quality employees to make these components. We recognize how important local talent is to our success as a company and the immense value they bring to Davies Molding. We will continue to support local recruiting events, like manufacturing day to find the best talent available for the future growth of Davies Molding.

Davies will be steadfast in our dedication to serve our customers and provide our local community employment opportunities at our world class Injection and Compression Molding facility. Visit our new website to learn about our famous knobs and plastic products that we manufacturer every day. If you are a local school or other training facility and would like to schedule a visit to teach your students about manufacturing of plastic and composite components, contact us at (800) 554-9208 and we can schedule a visit. We believe that the future of Davies Molding depends on the youth of today.

Thermoset plastic molding is an advanced manufacturing process that enables the creation of highly customized parts with enhanced design flexibility, superior strength, exceptional durability, and excellent chemical resistance. Unlike thermoplastics, thermoset products maintain their structural integrity over time, making them ideal for demanding environments where quality is crucial. Additionally, the minimal shrinkage exhibited by thermoset products during the curing process allows for intricate details and precise customization options, further expanding their versatility. Thermoset plastic parts are produced by utilizing heat and pressure to transform raw materials into precisely shaped parts. In contrast to thermoplastic molding, thermoset molding involves the application of high pressure to room temperature pellets or powders, which are then introduced into a heated mold. Within the mold, the polymers in the material undergo cross-linking during the curing process, resulting in an unbreakable and irreversible bond. The pellets or powders used in this type of molding commonly consist of epoxy, phenolic, or polyester resin. While thermoplastic molding has traditionally enjoyed greater popularity, manufacturers are increasingly embracing thermoset molding due to its array of advantageous features.

What are the key benefits of thermoset molding?

1. 1. Design Flexibility: Thermoset molding allows for a wide range of design options. Including the ability to produce complex shapes along with details not available in traditional molding. This makes thermoset products an ideal choice for custom molding project.
   2. High strength: Thermoset plastics are known for their high strength and stiffness. This makes them ideal for producing thinner parts, parts with longer ribs, and other features that require high strength-to-weight ratio. Parts produced using thermoset molding can withstand high stress, making them suitable for applications where durability and reliability are required.
   3. High and low temperature resistance: Thermoset plastics are capable of withstanding high and low temperatures without melting, becoming malformed or broken. This means that parts produced using thermoset molding can be used in high-temperature or very low temperatures applications, where other plastic materials would not hold up 
   4. Low shrinkage: Thermoset plastics are ideal for applications where tight tolerances, precise measurements and details are critical. During the curing process, thermoset plastics experience minimal shrinkage allowing for more complex dimensions and details which are difficult to achieve with other molding processes. Plus, thermoset parts will retain their shape and size over time and in harsh environments.
   5. Chemical Resistance: The resins used in making thermoset parts are resistant to acids, alkalis, solvents, and oils making these parts ideal for more demanding environments.

What are some use cases for Thermoset?

Thermoset molding is a rapidly expanding option across many industries as companies look for parts that can hold up under extreme conditions. Below are some of the industries where you will find thermoset molded parts:

1. 1. Electrical: Thermoset parts are used for insulators, circuit breakers, transformers, and other electrical components where there may be high temperature or stress.
   2. Industrial equipment: Thermoset parts are used in pumps, valves, and compressors.
   3. Energy and power generation: Thermoset parts are used in wind turbine blades, solar panels, and power plants.
   4. Consumer goods: Thermoset parts are used in electronics, appliances, and sporting equipment.
   5. Construction: Thermoset parts are used in pipes, fittings, and roofing materials.
   6. Marine: Thermoset molded parts are used in boat hulls, decks, and interiors.
   7. Automotive: Thermoset molded parts are used extensively in the automotive industry for engines, electrical systems, and different components on the inside of the vehicle.
   8. Aerospace: In the aerospace industry, thermoset parts are used for aircraft interiors, engines, along with structural components.
   9. Medical devices: Thermoset parts are used in many different types of medical devices, including surgical instruments, diagnostic equipment, or implants.
   10. Military equipment: Thermoset parts are used in weapons, vehicles, and aircraft.

Thermoset molding companies offer this advanced manufacturing process that produces parts with a range of benefits over traditional plastic molding including better details, greater strength, higher durability, and superior chemical resistance. Thermoset molded parts are the perfect solution for companies seeking high quality customizable parts that will outlast standard plastic parts.