Category Archives: Custom Mold Plastic Products

Value Added Services

At DeKALB we offer an array of value added services to complement your molded plastics needs. We pride ourselves on the ability to provide our customers a wide range of services.

Our team has the ability to utilize existing products and fabricate them to create customized components. Our capabilities include cutting-straight and angles, assembly, bonding, welding, inserting, routering and drilling. At DeKALB, we also providing painting services, utilizing both solvent and water based painting systems with complete masking capabilities. We provide numerous painting systems, including: acrylic, water, and urethane based, as well as multiple masking, color, and textures.

DeKALB provides complete plastic and assembly solutions, from simple sub-assemblies to complete assemblies that are packed and shipped right to your customers’ door. We have the capabilities for sonic and induction welding, enclosure and component assembly, bonding and emabonding. We also have the capability of specialty packaging, bulk packaging, and consumer-ready packaging with custom labels and decals.

Our numerous years of experience in the manufacturing industry guarantees the highest quality products at the right price. We keep track of these products with our inventory management systems. These solutions reduce your work load and increase the efficiency of your supply chain.

At DeKALB, we are constantly looking for new ways to make operations for our customers more efficient.

Custom Molded Plastics

Custom molded plastics are the heart and soul of DeKALB Molded Plastics. DeKALB is one of the first ISO 9002 certified structural plastics molders in the United States. With presses ranging in tonnage from 300 to 750 tons and over 30 years of experience in the structural foam industry, there isn’t a project the team at DeKALB can’t tackle with precision and quality.

DeKALB specializes in large, multi-nozzle plastic products while offering in-house painting, decorating, kitting, and assembly capabilities. Deliverables range from single stand-alone products to complex, multi-component, multi-operation programs.

DeKALB’s product offerings are diverse and focused, including:

In the Specialty Material Handling market, DeKALB produces rigid plastic pallets, folding transport boxes (for bulk and liquid products), and other applications that protect valuable and perishable household items (food, textiles, and medical components). In the Medical market, DeKALB produces a variety of intricate products, ranging from ultrasound and densitometers to MRI helmets and medical beds. Their main concentration is to produce products that contain, support, and protect medical equipment. DeKALB’s Safety Enclosures and Devices focus on protecting and preventing individuals and property from harm with the creation of barriers, stands, and guardrail blocks.

DeKALB has perfected two main plastic manufacturing processes: structural foam and gas assist. Structural foam molding (Fig. 1) is a process in which foamed plastic flows through the mold, surface cells explode, and a solid skin forms against the walls of the mold. Meanwhile, the core of the newly created part cools to a cellular structure. The end result is a part which is up to 20% lighter and three to four times more rigid and durable than solid plastics. This innovation can replace a myriad of materials, including wood, metal, concrete, and fiber glass.

structural-foam-molding-process

The gas assist molding process (Fig. 2) utilizes nitrogen gas that is injected into the polymer melt as soon as the resin is injected into the mold. The nitrogen displaces the polymer in thicker areas, hollowing out the part and making it significantly lighter. This is a low-pressure injection method that prevents sink marks and the ‘characteristic swirl’ that occurs during structural foam processing. In addition, cycle time is reduced due to faster cooling, equating to a lower cost component.

gas-assist-injection-molding-process

Beyond competitive pricing, DeKALB prides itself on superior customer service, warehousing capabilities, and on-time deliveries. One glance at the Client Testimonials page on dekalbplastics.com tells the story of DeKALB’s consistency, quality, responsiveness, competitive pricing, and technical support.

Custom Foam Molding: Process, Solution, Success

It’s a Thorough Process:

At DeKALB Molded Plastics, our team excels at providing comprehensive custom foam molding solutions for (structural plastic) molded products.  When added value is required on a part such as painting, kitting or fabrication, DeKALB is your single source for custom foam molding solutions. We provide design assistance, will engineer the optimum moldability of a part, and manufacture custom-molded structural foam to print specifications. And we do it quickly and cost-effectively.

  • Engineering support with MoldFlow
  • Design Assistance
  • Complete Project Management
  • Strong Expertise and Internal Resources

It’s a Complete Solution:

DeKALB has built a reputation around high quality standards for structural foam materials. We are committed to providing innovative ideas to the part development process, but more importantly, building long-term relationships through superior customer service. To maintain a high level of service and quality, our team meets each morning to review the progress of every project and net out daily goals. The overall goal is to pass our knowledge and expertise in structural foam materials directly to our customers and set the bar high for long-term success.

It’s a Group Success:

DeKALB offers superior customer service as this is critical to the success of our business. The company is committed to meeting customer requirements for delivery, quality, responsiveness, pricing and technical support. That is how DeKALB aims to become our customers’ single source for plastic and assembly needs. We’re proud of the fact that the majority of our customers have been with us for many years.

Dynamic Opportunities in Focused Markets

DeKALB Molded Plastics made a strategic decision in 2014 to focus on multiple market segments. Our goal is to expand our market focus to offer quality structural plastics to industries that promote better quality of life. Our main three segments are Medical Enclosures, Safety Devices, and Special Material Handling. Each brings their own unique value to DeKALB and provides the opportunity to display our capabilities in different ways.

Market Segment

Medical Enclosures – Typically are molded with engineered resins with value added operations such as inserting, painting, silk screening, and/or kitting. Volumes may vary in quantity. This segment meets our core competencies both from a molding and finishing perspective.

Safety Devices – Safety is the number one focus within DeKALB and anytime we can provide product within that industry, we consider it a win. In addition, we currently have a customer using 100% recycled material in their product. Not only are we providing a safety product but also focusing on being green.

Specialty Material Handling – This segment goes well beyond pallets. Any product used to store or transfer could be placed in this market segment. The structural foam process provides product that is light weight yet durable in strength. In addition, not only are virgin materials utilized in these products but also regrinds to save on costs.

Our development processes are continually improved and perfected to fit the needs of specific industries. As we continue to expand our offerings and capabilities, we have researched other market segments, such as Recreational and Lawn/Garden. DeKALB is always looking for new opportunities and strives to offer the highest quality of products and service. While we focus on our deliberate market segments, each are carefully evaluated to ensure the needs are within our capabilities and align well with DeKALB’s overall growth strategy.

What is DeKALB’s plastics manufacturing size capabilities?

Transcript:

Many people come to DeKALB Molded Plastics because we can make large parts. Large parts, structural foam, gas assist, very, very well. We can make products up to 150 pounds at our facility, but really it’s the type of process that we can do. Because they are so large, we can be cost effective with the rate reduction, and again, providing the characteristics that you need for your large part. We present warp, creep, all the building stresses that come with an injection molded part go away with structural foam.

How can DeKALB help with plastic injection needs?

Transcript: DeKALB Molded Plastics is a custom molder of injection plastic products. We specifically do structural foam, gas assist. You may have an idea and you’ll have a basic concept and we are able to produce the entire product for you. You bring us your idea and we’ll take it from concept to finish production. We will assist you with design. We will connect you with the tool shops. We will provide those services. We will launch your product for you, and then we will be your producer. You still will own the tool. It’ll be your product, but we will be your manufacturing arm.