plastic injection molding

case study
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the problem
A global leader in automotive lighting came to PHB with the challenge of creating two castings – one for low beams and one for high beams. Because of the complexity in aligning the fixtures (heat sink pads) for the LEDs, prior designs had only allowed them to have three heat-sink pads per casting. Since both the low beams and high beams required six heat sinks, each headlight required four castings. The problem compounded when the mirror design was required for left or right headlights. With the added expense of creating separate tooling for all of the castings, and the additional time and expense involved in aiming these eight castings, our customer realized it was time for a new solution.
the solution
The challenge in producing the six heatsink pads was to maintain the profile tolerance to the 6 pads to within .4mm to the datum structure. There are 17 individual features at each pad location, or 102 total features per casting that are critical to function. Any missing feature results in a part that our customer cannot fully assemble. PHB utilized the MAGMA process simulation and other camera quality inspection, close tolerance machining, and precision quality control to develop and produce a two-casting headlight assembly for our customer.
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Why PHB Leads Among Custom Plastic Injection Molding Companies

  • PHB Molding Division can provide high volume injection molded plastic products
  • We have a full range of capabilities from plastics prototyping, to tooling, and production
  • With a range of plastics types and processes, PHB solves problems in plastic molding globally
PHB Plastics Molding offers you the ability to design and build tooling while assisting with the design of the product. We also provide plastic part prototyping, assembly, over molding, product graphics, custom packaging and shipping. Our plastics molding company runs three shifts of productions including both low volume and high volume jobs. We can rework older plastics molding tooling as well as provide specific testing and compliance certifications. PHB Plastics Injection Molding is ISO 9001-2008 Certified. We utilize Electronic Data Transfer, Kanban and JIT production scheduling to meet customer requirements.

plastic molding Capabilities

PHB not only prototypes, designs and manufacturers injection molded plastic products, but we do so with an unmatched attention to detail. Through constantly improving processes and a culture of innovation, our plastics molding division has become a world leader in the development and manufacturing of products. We have partnered with well-known brands to design parts for everything from upright mobility devices, to finished parts on luxury automobiles. Some of the materials and products we utilize include:

Molding Thermo Plastic Products

  • ABS
  • PC
  • Nylon
  • Delrin
  • Valox
  • Ultem
  • Insert Molding
  • Overmolding (Santoprene-PP/Nylon)
  • Tapping
  • Santoprene
  • Glass Filled Materials
  • Sonic Welding
  • ABS
  • PC
  • Nylon
  • Delrin
  • Valox
  • Ultem
  • Insert Molding
  • Overmolding (Santoprene-PP / Nylon)
  • Tapping
  • Santoprene
  • Glass Filled Materials
  • Sonic-Welding

Molding Thermo-Set Plastic Products

  • Durez Phenolic
  • DAP
  • Polyester
  • Plenco Materials
  • Durez Phenolic
  • DAP
  • Polyester
  • Plenco Materials

PHB Plastics Injection Molding Markets include:

  • Railway
  • Appliance
  • Automotive
  • Electronic
  • Military
  • Aerospace
  • Medical
  • Safety Appliances
  • Transportation
  • Industrial Products
  • Home Products
  • Railway
  • Appliance
  • Automotive
  • Electronic
  • Military
  • Aerospace
  • Medical
  • Safety Appliances
  • Transportation
  • Industrial Products
  • Home Products

Plastics Insert Molding

PHB Molding produces overmolded products in both Rubber and Plastic. The following is a list of examples to showcase the spectrum of our injection molding capabilities:

  • Molding Thermo-set rubber over Glass Filled Nylon with a Chemlok Adhesive that will provide both a mechanical and chemical bond between the two parts
  • Over molding of brass or steel threaded inserts into thermoplastic parts
  • Post Sonic welding threaded inserts
  • Over molding Thermo-set plastic on Metal products

Other Services

PHB provides a number of value added services to serve our customers and keep lead times at a minimum. These services include:

  • Custom trimming of plastic products
  • Custom assembly as required for variations of product versions
  • Special labeling and assembly of both Plastic and Rubber products
  • Cryogenic Deflashing of plastic products
  • Creating multi-colored, decorative silkscreen labels and logos
  • Rubber Surface Finishing, Gluing, Cryogenic
  • Special packaging

choose phb for your plastics molding needs today

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