Mold Flow Simulation Analysis for Custom Molding

Posted by Jenny DuPrey, Marketing Manager at Davies Molding

Mar 24, 2016 12:00:00 PM

The Davies Molding engineering team utilizes mold flow analysis software to create tooling for new custom molding projects.  Mold flow analysis simulates the flow of plastic into the mold cavity during the injection molding process.  It provides a qualitative analysis of the quality of the part that will be produced.

Mold flow analysis can predict if changes will be needed with the wall thickness, gate location, material or part geometry.  Combined with 3D printing, it's faster and less expensive to perform a mold flow analysis than making physical prototypes to test.  The analysis is especially useful for parts that will require plating, as knit line locations are important to know.


Mold flow analysis benefits include:

  • Eliminate costly re-work
  • Improve part quality
  • Accelerate time product reaches the market
  • Troubleshooting steps and practical design advice to help diagnose and avoid potential problems

Davies Molding custom part process


Learn more about our engineering capabilities by visiting or email us at


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Topics: Custom Molding

The Impact of 3-D Printing on Custom Plastic Molding

Posted by Becky McMorrow, Marketing Manager at Davies Molding

Jan 15, 2014 9:00:00 AM

How does 3-D printing technology affect an 80 year old plastic knob and custom plastic parts manufacturer?  That was one of the questions that was asked to Derran Smith, President of Davies Molding, in a recent interview on CEO Intronet.

“The advancements in 3-D printing is growing everyday,” said Derran in the interview. “It can help our customers build and tweak a finished product to the exact point where they know it is going to work before we invest in cutting significant tools steel, which saves everyone time and money.”

metal-to-plastic-part-conversion3-D printing prototypes are often very helpful when converting a metal part to plastic.  Plastic parts are dent-resistant and lighter, and utilizing 3-D printing to prepare the prototypes allows the conversion process to move faster. Davies Molding has manufactured several metal to plastic conversion parts for the food service, commercial HVAC, and automotive industries.  Details of these projects can be found in our custom molding portfolio.

Want to learn more about metal to plastic conversions?  Download our free ebook “The metal to plastic conversion guide to reducing costs”


View Derran Smith’s complete interview below or click here.

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Topics: Custom Molding

The New Trend in Industrial Shift Knobs

Posted by Becky McMorrow, Marketing Manager at Davies Molding

Jan 2, 2014 9:51:35 AM

Shifter knobs can be found in vehicles, cranes, tractors, and other types of machinery where manipulating gears are required. Davies’ shifter knobs can be customized to meet specific requirements such as operating instructions or customer logos. Secondary operations include laser engraving, pad printing, or hot stamping, applying inlays or mylars, color matching, drilling, machining, and a new finishing trend- hydrographic printing.

decorative-finish-industrial-shift-knobsHydrographic printing is a popular trend for adding customizable designs, colors, and textures to shift knobs.  As you might have guessed, it's a water-based printing process and a  high gloss polyurethane hydrographics clearcoat makes the printing durable and long-lasting.

 Spectrum Industries, does a good job of describing the process in 6 easy steps.

1) Parts are loaded onto custom tooling.

2) Parts are prepped by washing or painting.

3) Parts are dried.

4) Parts are dipped in the hydrographic printing bath.

5) Top coat is applied based on the application for the part.  Exterior and Interior durability options.

6) Parts are inspected before shipping.

Check out this neat video of how hydrographic printing works.

Plastic knobs designed for heavy equipment and industrial use are available in a wide range of sizes, but the most popular are ball and lever knobs.  Our ball and lever knobs come in a variety of styles and sizes and are available in phenolic, nylon, or polypropylene. Phenolic materials are typcially stonger that thermoplastics like nylon, and are a popular choice for durable, long-lastic shifter knobs.  However, thermoplastic materials such as nylon have a high impact strength, and can be molded into just about any color you can dream up.  And now with hydrographic printing, you can choose the material you want and add a customizable finish that makes it yours.  Want more information?  Check out our hydrographic printing info page or call us at 1-800-554-9208.

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Topics: Plastic Knob Insert Molding, Custom Molding

Custom Molding: Choosing the right material for your plastic knob or handle

Posted by Becky McMorrow, Marketing Manager at Davies Molding

Dec 5, 2013 7:44:03 AM

Nothing is more important than choosing the right material for your plastic knob or handle.  Careful consideration of the end user and application can save time and money in the long-run.  Don’t know where to start?  Here is list of materials and their applications to get you started.  Talk to our highly trained technical sales and engineering staff if you have questions.  We work with hundreds of various materials and constantly reviewing new materials as they come on the market. 




Applications and Uses


Extremely rigid, high melting point, high strength, good frictional properties, resistance to fatigue

Gears, bearings, bushings, cams, housings, conveyors, plumbing fixtures, gas tank caps, automotive door handles, seat belt components, and zippers


Exceptional resistance to long-term exposure to sunlight and weathering, outstanding clarity, good light transmission

Swimming pools, skylights, sinks, washbasins, room dividers, and the tail lights on automobiles

Acrylonitrile-Butadiene-Styrene (ABS)

Outstanding impact strength and high mechanical strength, great as a substrate for metalizing

Appliances, automotive parts, pipe, business machines, telephone components, shower heads, door handles, faucet handles, and automotive front grilles


Known for their stability and adaptability

Automotive parts, electrical and electronic applications, and packaging


Exceptional mechanical, thermal and chemical resistant properties

Aerospace, heavy equipment, and automotive


Known for its strength, toughness, chemical resistance, and high melting points

Automotive, appliances, electrical and electronic applications, ovenware, and outdoor lighting

Thermoset Materials



Applications and Uses


Excellent heat resistance, dimensionally stable under components,excellent dielectric strength

Electrical applications like circuit breaker insulation, switchgear, cases, housings, capacitor and resistor encapsulation, automotive parts, and coatings

BMC (Bulk Molding Compound)

Highly rigid, impact resistant, exceptional physical and aesthetic properties, high strength-to-weight ratio

Appliance parts, electric and electrical components, HVAC components, industrial light housings, automotive, recessed lighting baffles

Diallyl Phthalate (DAP)

Virtually no post-mold shrinkage, high impact resistance, resistant to sudden and extreme jolts and severe stresses, recommended for very high temperatures, chemical resistant, fungus resistant

Cross-linking agent, thermosetting molding powders, casting resins, and laminates, military, electronic components


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Topics: Custom Molding

Custom Knobs: just like Burger King- we make them your way!

Posted by Becky McMorrow, Marketing Manager at Davies Molding

Nov 13, 2013 7:37:55 AM

Having the right color part is very important for many applications that require knobs, either because it is functional, industry or product specific, or for appearance. The standard color for phenolic material is black. Other colors are available, but usually cost more. Red is the second most popular phenolic knob color, typically used for ball or lever knobs.  phenolic-balls

Unlike thermoset phenolic, thermoplastic materials have a very wide range of available colors. In many cases you can match your color target exactly to a PMS number.



In addition to color, knobs can be customized with a variety of finishes.  One of the most popular finishes is laser engraving, and then pad printing, for adding instructions or a logo to your knob.  At Davies Molding, we have over 80 years of experience making custom knobs for companies in a wide range of industries.  We will be happy to assist you in choosing the right finish for your application. Contact one of our experienced account representatives at 1-800-554-9208, who will be happy to assist you with your knob needs!

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Topics: Custom Molding

Custom Plastic Molding for Valve Controls

Posted by Becky McMorrow, Marketing Manager at Davies Molding

Nov 8, 2013 5:00:00 AM

There are a variety of plastic knobs that are particularly suited for manual valve controls.  “T” or Bar knobs are the most popular plastic knobs used for manual valve control applications. Here are examples of different shapes of bar knobs available.  


Options for custom molding your Bar or T Knobs include:
  • Variety of thermoplastic and phenolic materials
  • Sizes ranging from 1-1/32” to 3-3/8” in diameter
  • Female insert, projecting stud and thru-hole options. 
  • Knobs can be decorated  or branded to your specific need.

Contact Davies Molding for a free sample or call us at 1-800-554-9208 to discuss your custom molding needs.

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Topics: Custom Molding

Made in the USA Butterfly Valve

Posted by Becky McMorrow, Marketing Manager at Davies Molding

Nov 1, 2013 1:40:23 PM

butterfly-valve-thermoset-moldedWe have a long history of manufacturing plastic knobs, especially phenolic plastic knobs.  But we also mold phenolic custom plastic parts, such as the plastic butterfly valve for the oil & gas industry. We started manufacturing butterfly valves a few years ago because the company that needed them got fed up with their overseas vendor. 

Long lead times, poor communication, and inconsistent quality from their overseas vendor made them decide to source domestically, and Davies Molding got the call to quote. We were able to manufacture a butterfly valve that met their strict quality standards and short lead times.  We chose a compression molding process using a phenolic material that is chemical and water resistant – key attributes for a butterfly valve.  We now manufacture a large range of sizes of butterfly valves along with other custom compression molding. 

Check out our custom molding portfolio for more information or contact us for a custom quote.


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Topics: Custom Molding

Reduce Costs by switching your metal parts to plastic

Posted by Becky McMorrow, Marketing Manager at Davies Molding

Sep 30, 2013 7:47:12 AM

metal-to-plastic-water-tankAre your metal parts rusting or denting?  Do you need multiple operations such as welding and bending to machine your metal part?  If you answered yes to either of those questions, you should consider switching to a plastic part.  Plastic parts resist rust and denting, can be custom colored, and have high impact strength - not to mention are cheaper to produce.  Want to learn more?  We've put together a 24-page ebook to help you learn more converting metal to plastic parts and about the molding process-click here to download the guide, or call to schedule a design consultation today.  Visit our product portfolio to learn more about metal to plastic conversion parts for the Automotive, HVAC, and food Service Industries.
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Topics: Custom Molding

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