Experience Quality

The healthcare, automotive, and filtration markets demand increasingly complex products with ever-tighter tolerances, which is why GW Plastics has taken injection molding to a higher level. GW Plastics Scientific Molding (GW/SM™) reduces defect occurrence to ensure the highest integrity of product quality over the life of the project, regardless of molding machine, material, or manufacturing location.

Utilizing GW/SM™ techniques, we develop process characterizations that will ensure high-quality, repeatable molded parts despite normal (expected) variation in materials and processing equipment. All molds, whether new or transfer, are put through our rigorous statistical qualification process so that, regardless of manufacturing location or machine, the same critical molding parameters will be achieved. GW Plastics works to continuously refine our scientific injection molding processes and integrate solutions that reflect our lean manufacturing commitment to improve efficiency and reduce waste.

Efficient Injection Molding Technologies

GW Plastics utilizes advanced scientific molding technologies to maximize manufacturing efficiencies and offer our customers a one-stop supply chain solution. To reduce costs, improve quality and streamline our customer’s supply chain, we have invested in robotic-assisted molding technologies, including thermoplastic and Liquid Silicone Rubber (LSR) molding, multi-shot and multi-material molding, automated insert molding, thin wall molding, precision gear molding, and ultra-small part molding.

Two-shot, multi-shot, and multi-material molding allows for complex part production in one molding operation for improved product design, performance, and cost. With GW Plastics’ advanced injection molding and tooling capabilities, a soft thermoplastic (or LSR) and a rigid thermoplastic are molded together to create a more functional product without the additional cost or production complexity of assembly and other post-molding operations. The advantages of this process include:

  • Cost effective assemblies due to elimination of secondary operations
  • Improved quality from less part handling and possibility of contamination
  • Reduced validation cost by simplifying the molding process flow
  • Increased design flexibility through enhanced material combinations and part consolidation

For applications where multi-shot methods are not practical based on quantities or geometries, insert molding and over-molding can achieve the same result. Our use of automation for insert feeding and cutting-edge silicone flashless molding techniques guarantees efficient and high-quality production. LSR ultra-small part molding is accomplished by using state-of-the-art injection machines and pumping technology designed for silicone molding to create precise parts with high shot-to-shot repeatability.

Learn more about our scientific molding process development growth

Why GW/SM™?

  • GW/SM™ techniques ensure high-quality, repeatable production
  • Produce quality parts despite variations in molding materials and equipment
  • Proven systematic methodology involves rigorous statistical qualifications
  • Development of robust processes regardless of manufacturing location
  • Can be used on all new/transfer
  • Mold-specific process development (rather than machine-specific)
  • Improved time-to-market and quality

Critical Steps to Scientific Injection Molding

  • Mechanical cycling
  • Short shot analysis and fill study
  • Viscosity curve and gate freeze
  • Balance of fill between cavities
  • Pressure loss through system
  • Quality inspection and dimension review
  • High/low challenge
  • Weight study
  • Document process sheet
  • Cavity pressure transducers and pressure versus time curves

GW/SM™ Advanced Molding Capabilities Include

  • Thermoplastic and Liquid Silicone Rubber (LSR) molding
  • Multi-shot and multi-material molding
  • Automated insert molding
  • Thin wall molding
  • Precision gear molding
  • Ultra-small part molding
  • Cleanroom manufacturing
  • Integrated molding and assembly