Working With Custom Thermoplastics: What OEMs Need to Get Right Before Molding

Within the injection molding space, custom thermoplastics can allow for better part performance. However, they can introduce risk if poorly specified. Material behavior will impact tooling, cycle time, wear, and consistency throughout the manufacturing process. That’s why it’s so important to partner with an execution-focused manufacturer like Thogus. We help OEMs apply customer thermoplastics successfully at scale. Below, we’re exploring how custom thermoplastics offer opportunity and what you need to do to avoid risk.

Why Custom Thermoplastics Create Both Opportunity and Risk

Custom thermoplastics offer great opportunities for businesses. They allow engineers to adjust a material for a specific job instead of designing around a generic plastic. Adding fillers, fibers, or additives allows for better strength, stiffness, heat resistance, UV stability, and more. Often, this is at a lower cost than switching to a high-performance base resin. In many cases, custom solutions allow businesses to reduce part weight and create designs that wouldn’t be possible with unmodified thermoplastics. 

While custom solutions offer benefits, they also introduce risk. Additives can change how the plastic flows in a mold, how it shrinks as it cools, and how it wears tooling. A material that tests well in the lab can warp, short-shot, or damage molds in real manufacturing. That’s why it’s so important to work with an experienced manufacturer who can guide you to the right material.

What Must Be Defined Before Tooling Begins

To avoid potential risks, you must keep in mind a few considerations before creating your tooling. This includes:

• End-of-use performance vs. manufacturability tradeoffs
• Tolerance sensitivity and fiber orientation risk
• Expected volumes and lifecycle requirements

A qualified custom thermoplastics partner can help you evaluate your needs and match you with the right solution. 

How Thogus Helps OEMs Apply Custom Thermoplastics Successfully

At Thogus, we work closely with our clients to ensure the successful application of custom thermoplastics. Early design for manufacturability (DFM) and mold flow collaboration is the first step. We’ll get involved early in the design process to ensure the part can be molded well. Then, we’ll complete mold flow analysis to predict how molten plastic will fill a mold. That way, we can catch any problems before tooling is built. 

Along with that, we’ll suggest tooling strategies designed for material longevity. Some thermoplastics may be abrasive or have other characteristics that can quickly wear out molds. We design and select tooling with the specific material’s properties in mind, which helps us extend tool life.

We’ll also offer processing guidance based on real production behavior. Our shop-floor experience helps us advise on temperatures, pressures, cycle times, and other processing parameters. 

Getting Custom Thermoplastics Right Starts Before Molding With Thogus

Working with the right partner can help you get the best results out of your custom thermoplastics. At Thogus, we validate materials, tooling, and process decisions before they create downstream risk. We focus on repeatability, tool health, and process control across millions of cycles. That’s why we’ve become one of the leading injection molding companies in Ohio. Since 1950, we’ve been providing top high-volume injection molding services for businesses throughout the United States. 

We provide complete end-to-end solutions with Kanban and other inventory management systems, combined with 24/7 operations, to offer just-in-time deliveries. Combined with our customer-first focus and team of experts, we’re ready to take on the most challenging tasks. When you need medium- to high-volume contract injection molding you can trust, turn to Thogus.

Let’s Get Started

Want to learn more about what we can do for you? Reach out to our team today for a consultation.