Category Archives: Custom Molding

What is Custom Foam Molding?

There are many misconceptions about what custom foam molding means and the advantages to using it.  Listen to DeKalb Molded Plastics as they describe what it means to have custom foam molded plastics and why someone might want a foam molded part.

Benefits of Converting Metal, Concrete and Wood to Plastic

The conversion of metal, concrete and wood components to plastic have delivered significant, and in many cases unmatched cost savings.

Most materials have a set of properties and characteristics that are commonly known for their current design and use. The primary consideration for a possible plastic material in any application is the effect of “normal” operating conditions. Characteristics of plastics are offered in a wide range to suit your needs for tensile strength, heat tolerance, and chemical resistance with over 70,000 resins available. Various fillers and additives allow flexibility in most plastic resins to meet specific criteria.

Things to consider in plastic selection:

  • Temperature requirements-what environment will the plastic be exposed to?
  • Can plastics reduce the steps required to make a product?
  • What are the dimensional requirements?
  • Will the part require physical characteristics for heat or electricity conduction?
  • Does the part come in contact or have exposure to chemicals? What kind?
  • Investment in tooling

The primary benefits of plastic are:

  • Weight reduction
  • Strength to weight ratio
  • Lower cost
  • Reduce the number of components in an assembly
  • Incorporate recyclable materials
  • Can be integrated with other materials
  • Reduce manufacturing scrap costs

DeKalb Molded Plastics offers expertise in plastic product design, material selection, molding, finishing and decorating that provides the solution to your product needs.

Surviving the Recession

DeKALB Molded Plastics celebrated their 30th Anniversary of business in the Structural Plastics industry in 2009. Much has changed over those 30 years — from the structural foam products they first produced to the techniques they now employ to run the business. From products such as the first swimming pool panel, to the computer housings, and now on to the complex medical cabinetry—DeKALB has maintained their primary focus of “providing customer satisfaction that is unequaled in the Structural Plastics Industry”. Over the past 30 years, however, more has changed than just a few machines and the products DeKALB creates. DeKALB has become an ever-changing company in the midst of economic crises, and meeting the needs of its customers.

The president of the company, Rick Walters, said that DeKALB Molded Plastics has been through downturns in the economy before and they have learned how to manage through the tough times. They “know how to plan when business gets tight”, but this time they were going to have to “anticipate even less” in order to stay ahead of the recession curve. To ensure survival for both DeKALB and their customers, lower costs and higher value of services had to be made available.

Recognizing that this recession was going to touch virtually all companies, DeKALB knew their customers would be implementing some of the same financial strategies they would be forced to consider. Cutting inventories, staff, and general expenses would be the norm. But rather than “hunker down”, DeKALB chose to be proactive. They knew they would have to provide options and solutions to help their customers weather the storm. They chose to take customer service to a new level.

DeKALB decided to be aggressive, to invest and grow; positioning to support their valued customers and to prepare for the return of the better economy. First, a new Sales Team was established. Amy Aleshire, Sales Administrator, was promoted to oversee all existing accounts. She works closely to better understand each customer’s needs, for today and the future. A new position was added to focus on new business opportunities. Darryl Warren, New Business Development Lead, was hired. His mission is to find new and non-traditional applications for the future. A marketing initiative was launched. SMP of Milwaukee, led by Teresa Schell, is helping share the DeKALB message with those looking for a plastics solution partner.

Understanding that to meet their customer’s needs DeKALB had to be better every day, they partnered with Harbour Results Inc. to lead and train them in Lean Continuous Improvement techniques. At DeKALB, they are learning how to cut back on all forms of waste, make their products more environmentally friendly, and shift their overall focus even more towards serving their customers. Over the next few years, DeKALB will expand further into their local and global communities, to help people learn that plastics can be a safe and efficient product for thousands of different uses.