What are Characteristics of Gas Assist Molded Parts?

Transcription: A gas assisted injection molded part is going to have a little more of a look like a high pressure injection molded product. There won’t be a lot of swirls. It’ll be more of a solid look, but still, won’t be a perfect class A surface. Adequate for most applications, it still is a very structural product. It has the gas channels but will look a lot like injection molding.

DeKALB is kicking off our annual United Way campaign

It’s that time of year again.


DeKALB is kicking off our annual United Way campaign. Our goal for this year is $14,500, which shouldn’t be a problem since last year we exceed our goal by $4000!! This is a big event that typically results in 100% employee participation. We have games and weekly fund raisers throughout the campaign to help raise money and then wrap it up with a lunch to celebrate our success. This is a great opportunity for our employees to have fun while supporting our community.

DeKALB Molded Plastics attending MAPP 2013

The DeKALB team is looking forward to attending the 2013 MAPP Benchmarking Conference. Meet two of our newer employees who will be attending the conference for the first time by watching this video. We are excited to see our friends and colleagues next week!

What is structural foam molding?


Structural foam molding is a process in which we use similar thermoplastics but you use blowing agents and you use colorants, and the blowing agents allow you to expand the material into the mold at a much lower pressure than you would on a high injection pressure system. What that does that gives you very good structural strength, it gives you the ability to save between 15-20% of your thermoplastic materials, it gives you the ability to make larger parts of that structural condition that you may not be able to do within a high pressure injection molding process.

DeKALB Molded Plastics featured in Manufacturing Today

The summer issue of Manufacturing Today highlights DeKALB Molded Plastics' commitment to strategy and investments which support not only the manufacturing process but also employees.

An excerpt of the article:

Founded in 1979, DeKalb Molded Plastics has spent more than 34 years building its reputation in the structural foam industry. A custom structural foam molder, DeKalb specializes in structural foam injection molding and gas assist molding, and large, multi-nozzle plastic products.

DeKalb was one of the first ISO 9002-certified structural plastics molders in the United States. Among the company’s services are in-house post mold painting; plastic decorating capabilities; kitting and assembly requirements for programs for single standalone products; or complex, multicomponent, multi-operation programs.

Read the entire article about DeKALB Molded Plastics.

Can Dekalb create my custom molding product?

We basically stay within the range of high density polyethylene to engineering structural plastics. If we go into the high temperature stuff where you’re going to need a oil heater, something beyond that 700-800 degree melt range, really, if the tool needs to be above the boiling temperature of water, and then we don’t play in that zone. In that area, in the three-sixteenths to quarter to three-eighths inch part thickness, four pounds to 150 pounds, that’s kind of our boundaries.

DeKALB Molded Plastics honored twice from PlasticsNews

Butler, IN – Structural foam molder, DeKALB Molded Plastics was recognized as the 2012 Processor of the Year finalist at the annual PlasticsNews Executive forum on March 6, 2013. DeKALB was nominated for this prestigious award by suppliers Kibbechem, FGL Precision Works, Plastic Solutions; customer Trinity and CPA Baden, Gage and Schroeder. The criteria process includes a comprehensive view in seven categories: financial performance, quality, customer relations, employee relations, environmental performance, industry/public service and technological innovation.


DeKALB was honored with a second award, the PlasticsNews Excellence Award for Employee Relations. The positive attributes at DeKALB Molded Plastics not only recognize excellent cash and inventory management but a strong commitment to the employees. President, Rick Walters supports the successful wellness program promoted by Human Resource Manager, Kassy Davis. In addition, Walters honors each employee on their anniversary by sharing a breakfast, lunch or dinner. A tremendous advocate to the community, each employee participates in a charitable activity that represents their passion whether it’s Big Brothers/Big Sisters, United Way, DeKALB Humane Society, or local schools to encourage manufacturing.

DeKALB is a premier molder of large structural foam parts, employing 130 people at its 80,000 sq. ft. headquarters in Butler, IN. The main market focus for the company is medical cabinetry, specialty material handling, safety products and lawn & garden.


What Does It Mean to be a Custom Plastics Molder?

We do not design custom plastic molding from scratch.  We are a custom molder.  DeKalb Molded Plastics takes designs that other people have to create the product.  Sometimes that has been a napkin that may even have had a beer or coffee stain on that napkin and start to work with that so we can estimate the job.  We can get other people involved, like actual design firms, and help move this idea to a product in hand.  DeKalb is not set up to be plastic product designers for product molders.

DeKALB finalist for PlasticsNews Processor of the Year

AKRON, OHIO (Jan. 7, 4:20 p.m. ET) -- Three custom molders -- injection molders Hoffer Plastics Corp. and Rodon Group LLC and DeKalb Molded Plastics Co., which does both structural foam and injection -- are the finalists for Plastics News’  Processor of the Year Award.

A team of judges from the PN editorial department in Akron picked the finalists.

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