Tag Archives: DeKALB

Is Gas Assist Molding with DeKALB Right for You?

When you see a smooth-looking finish on an industrial panel or on the blades of an air turbine, there is a good chance gas assist molding was used to manufacture this product. Many products we use every day require a brighter, smoother finish that will help enhance its performance, and gas assist molding achieves that every time. Through this process, nitrogen gas hollows out thick wall sections in a molded product. Then by combining air pressure with heat, the process creates a strong, robust part with a perfectly smooth finish.

DeKALB Molded Plastics delivers aesthetically pleasing, high-quality products for your industry with the help of gas assist molding. There is no room for error in the work we do, which is why all our products made with gas assist molding are flawless and functional.

What is Gas Assist Molding?

Gas assist molding is a highly technical type of injection molding that reaches beyond traditional design capabilities and processing limitations. This type of injection molding produces large plastic parts with complex designs. DeKALB Molded Plastics manufactures products through gas assist injection molding that makes life a little better and safer.

The high-speed, low-pressure injection method that DeKALB Molded Plastics uses in production is a competitive advantage. We utilize Milacron LPIM-Structural Web and Bauer Gas Assist technologies in our gas assist molding processes.

How Gas Assist Molding Works

Like standard injection molding, the process begins when a molding machine injects a short shot of resin into the mold. Then, just as the name suggests, high-pressure nitrogen gas is injected into the melt stream following the resin injection to assist. The nitrogen displaces the resin in flow or gas channels within thicker sections of the molded product. The end product will be hollow and have thick wall sections without sink marks or the swirl appearance typically characteristic of structural foam.

The flow path of the nitrogen gas depends on the resin flow in the cavity. Resin flow is determined by the volume and viscosity of the resin, not the nitrogen gas injection. Most thermoplastic materials can be used in gas assist molding.

What is Necessary for Success

In gas assist molding, the mold design and construction must be done correctly by experienced engineering and design teams. It is vital to have a shot control on the injection-molding machine that is both repeatable and accurate. Furthermore, the precision of time and pressure is necessary for achieving desired results with this technology. DeKALB Molded Plastics takes away any stress connected to these factors as we have the premier technology, tooling, and expertise to get the job done right.

Benefits of Gas Assist Molding

With less plastic material needed to produce the part, because the hollow areas are created with nitrogen gas rather than resin, gas assist molding can be a greener solution. The process of gas assist often allows for the consolidation of multiple parts into one. The process reduces or eliminates any need for secondary assembly processes. Additionally, with less clamping force required and a reduced amount of components under stress, gas assist molding can produce higher volumes with less frequent mold maintenance or repairs.

Gas assist molding has many other benefits, including:

  • The product will be lightweight while still being strong and firm. The nitrogen gas can form hollowed-out areas within parts (such as steering wheels, handles, etc.).
  • Gas assist injection molding produces more aesthetically pleasing parts. There is a reduced risk of flaws, sink marks, and shrinking with this technology.
  • When compared to standard injection molding, gas assist reduces cooling and overall cycle time.
  • Gas assist injection molding is an easy way to convert existing large metal parts to plastic, providing a better quality alternative.

Is Gas Assist Molding Right for You?

There are numerous benefits to gas assist injection molding as an alternative to various molding disciplines, including injection molding, rotational molding, blow molding, SMC, BMC, and die cast. If the product you need has a complex design, thick geometry, or both, gas assist molding is a great option to consider.

The DeKALB Difference

DeKALB Molded Plastics has earned its best-in-class quality reputation in the structural plastics industry. We are committed to solutions, and we manufacture products that make a difference. DeKALB provides large, high-quality components with value-add options such as painting, fabricating, assembly and more. Our highly skilled team trains to produce quality molded plastics every time.

At DeKALB Molded Plastics, we’re committed to your goals. Ready to start the conversation? Contact us today to learn more.

Grateful: A Thankful Letter from the President

As the year nears the end, this period always serves as a time of reflection, a time to look back and acknowledge the challenges while remembering the highlights. In most years, we sit around a table of loved ones and go around sharing memories. While we will remember 2020 for its unique tests, and our holiday celebrations might look different, there is still plenty to be grateful for this year.

At DeKALB Molded Plastics, this year began with an optimistic outlook.  We were committed to a strong year, leading with our strategic focus on safety. As our team planned our 2020 goals, we made it clear – we will never give up on anyone’s safety. No matter what, our goal remains the same - zero safety issues! At DeKALB, safety is everyone’s responsibility. From our employees to our guests, we are committed to protecting everyone who steps foot into our facility.

Dedicated Employees at DeKALB Molded Plastics

This year challenged our staff like never before. From adjusting to new safety policies to adapting to new COVID-19 protocols, our team has been excellent at being open-minded to change and continuing to come to work with a positive attitude.

I am so appreciative of the efforts of our staff. All of their hard work throughout the year has helped us gain new business opportunities and grow the partnerships of existing customers. Through it all, we were able to stay true to our core mission to provide unsurpassed satisfaction to all of our customers. I'd like to personally extend a thank you to the DeKALB staff for bringing energy and passion to the organization, buying into our process, allowing us to grow as professional individuals and as a business.

Our Customers – New & Old

To all of our customers, first and foremost, thank you for doing business with us. Without you, our business would not look the same. While this is true for any company, it resonates so much more this year as we have seen many have to scale back or close their doors.

This year required added patience as we all navigated through unscripted challenges. We cannot express enough how much we appreciate your loyalty, support and trust in DeKALB Molded Plastics to provide you with your structural foam needs. Thank you for believing in us, and we look forward to continuing to serve you as our on-going relationship continues to develop.

The DeKALB Community

Last and certainly not least, from our entire team at DeKALB Molded Plastics, we value the genuine relationship we have with our local community. From the day we first opened our doors, one of our core values has been to be an active member of our local community. To us, continuous improvement and care for our employees extend well past our walls and into our city. We dedicate our time to our community to help create a growing and supportive environment all around us.

We are grateful for the relationships that we have built within the area of Butler, IN. We are always happy to show our support as an active member of the community. While this year has had many canceled events, we were proud to still have the opportunity to give back through the annual United Way of DeKalb County Day of Caring event in September. However, one event that has been altered is our annual recognition dinner that honors members of the Butler Police Department, Butler Fire Department and locally stationed Parkview DeKalb EMTs. While the dinner is postponed, we will still be making a presentation of our support at an upcoming Butler City Council meeting next month.

I could go on about the many things I am indebted to, even in this time of challenge. Without the dedication of our staff, the support of our community and the confidence of our customers, DeKALB Molded Plastics would not be in business. For that, I am comforted, and I know the DeKALB teammates are too!

Thank you! Thank you! Thank you! – From all of us at DeKALB Molded Plastics

We wish you and your family a wonderful Thanksgiving!

 - Rick Walters