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PTI Engineered Plastics Company Overview
Macomb, MI - 165,000 sqft
About Us
- PTI Engineered Plastics is your single-source solution from advanced product development to production manufacturing.
- Our superior design, tooling operations and manufacturing systems ensure that your finished product exceeds your expectations.
This resource is designed to help you learn more about the wide range of services and capabilities offered by PTI Engineered Plastics. Feel free to explore this resource to see how PTI can be your single-source solution from advanced product development to production manufacturing!
PTI Engineered Plastics Virtual Tour
Virtual Tour Join us on a virtual tour of PTI Engineered Plastics, where we showcase our state-of-the-art facility and manufacturing capabilities. From design and engineering to custom molding and assembly, our team is dedicated to providing high-quality plastic components for a diverse range of industries. Get a behind-the-scenes look at our cutting-edge technology and processes, and see why we're a leader in plastic injection molding.
Our Services
For 40+ years, PTI has been your single source solution for plastic injection molding, manufacturing, product development, production, and assembly.
Design
Engineering
Tooling
Manufacturing
Automation
Value Add
Quality
Validation
Markets Served
PTI Engineered Plastics provides unparrelled services to the following markets:
- Medical
- Aerospace & Defense
- Electronics
- Mobility
- Consumer
Design
Product Development
We take great ideas and design them into manufacturable productsWhether injecting creativity into a current project or spearheading an entirely new product design, we seamlessly provide the path from an idea to reality — From mind to manufacturing.
- Product Research
- Concept Development
- Digital Renderings
- 3D Modeling
- Product & Component Design
Engineering
Engineered for Manufacturability
Design for ManufacturingEarly customer involvement in the Design for Manufacturing phase offers cost savings in product design and reduces lead time.Commercial Engineering Cost Estimators evaluate your product requirements to provide you with quotes that address every aspect of your project scope.Program ManagementA dedicated engineering team manages your project from design reviews to the delivery of precise parts. Quality EngineersOur quality engineers are well versed in IQ /OQ / PQ and PPAP requirements.Process EngineersOur process engineers are RJG certified Master Molders and utilize scientific injection molding principles to establish all nominal molding parameters.
Tooling
Quick to Market
PTI has built its reputation and success on the ability to get their customers’ products to market quickly and efficiently – without compromising mold design, part design, or quality.Functional Injection Molded PartsVertical integration allows us to quickly deliver adaptable, tooled parts for proof of concept.Alternate Material RunsAbility to evaluate multiple materials within the same set up.Bridge ToolingFunctional prototype tools are designed with production in mind and often used as bridge tools for early production runs. Rapid PrototypingFDM, SLA, SLS and Urethane Parts
Tooling
Built to Precision
On our Toolroom floor you’ll find a fully integrated tooling network comprised of mold designers and CNC programmers utilizing state-of-the-art software for our high-speed CNC vertical machining centers complimented by our plunge and wire EDM Machines. Toolroom
- 350 Tools Produced Yearly on Average
- Complete In-House Design
- Moldflow Analysis
High Speed CNC Machining
- Horizontal 4 Axis
- 3 & 5 Axis
EDM
- Graphite Machining Centers
- CNC EDM Centers
- Wire EDM Centers
Tooling
Tooling Capabilities
Complex tooling and molds are where we specialize.At PTI, we use an array of materials from aluminum, mild steel, hardened steels, stainless and copper beryllium to create prototypes, low volume, hybrid and production tooling. Materials
- Aluminum | QC-10
- Mild Steel | P.20, NAK 55
- Hardened Steel | S-7, H.13, D.2
- Stainless Steel
Mold Bases
- SPI Classifications | 101, 102, 103, and 104
Runner Systems
- Cold Runner
- Hot Drop and Hot Manifold Systems with Valve Gate Options
Asset Management
- Mold Repair & Maintenance
- Controlled Storage
Manufacturing
Technology Driven
Core Capabilities
- Low Volume Manufacturing
- 500 – 60,000 pcs
- Production Manufacturing
- 60,000+ pcs
- ISO Class 8 Cleanroom for Molding & Assembly
- 60 Injection Molding Machines
- 35 – 300 ton
- High Heat Molding
- Insert and Over-molding
- Automation
- Assembly and Value Add
- Part Decorating
- Real Time Production Management
Manufacturing
High Temperature Molding
One of Our Specialized ServicesHigh-temperature plastic injection molding is a specialized process used to shape heat-resistant polymers into precise parts. These polymers are ideal for extreme environments, where standard plastics would fail. The materials molded using this process offer enhanced thermal, chemical, and mechanical properties that ensure durability and performance.PTI Adheres to Strict Injection Molding Safety Guidelines
- Resin Temperatures as High as 850°
- High-Pressure Water to Accurately Maintain Mold Temperatures as High as 365°
- Flexible Automation for Safety and Repeatability
Materials – Our Wide Range of Engineered Grade Resins Include:
- Peek (Victrex)
- PPA (Amodel)
- PAI (Torlon)
- PPS (Ryton, Fortron)
- PEI (Ultem)
Manufacturing
Controlled Environments
Our 10,000 sqft. Class 8 Cleanroom provides manufacturers with an optimal environment to produce and package medical and/or other devices under strictly monitored and controlled conditions. A certified Class 8 Cleanroom is designed to eliminate external dust, volatile emissions and other contamination agents that could endanger the health of a patient. Cleanroom
- ISO Class 8 Environment
- FDA Registered
- Assembly
- Part Decorating
- Packaging
Automation
Precision Repeated
In today’s manufacturing environment, automation is essential to staying ahead of this ever-evolving industry. At PTI, we embrace this reality and actively integrate automation into our processes and operations. Below are some of the keyways we leverage the competitive advantages of automation here at PTI. Featuring
- MASS & MASS-R Units (Modular Automation Station System)
- MAR (Mobile Automation Robots)
- Sprue Pickers to Multi-Robotic Cells
- Complex Part Assembly
- In Line Part Inspection
- Decorating
Value Add
Precision Repeated
When your project requires more, PTI offers many value added services to add those finishing touches. Assembly
- Component Assemblies & Subassemblies
Plastic Joining Assembly Process
- Ultrasonic Welding
- Spin Welding
- Heat Staking
- Hot Air Cold Staking
- Thermal Insertion
Part Decorating, Labeling and Traceability Coding
- Laser Marking
- Pad Printing
Managed Services
- Painting and Plating
- EMI Shielding
Packaging
- Peel Pouches
- Custom Trays
- Kitting
Customer Involvement
Collaboration Initiative
Need to be more hands on? Come join us on site in one of our customer suites, where you can collaborate with our teams and get real-time feedback on your prototype or production program. Customer Suites
- Full Access to Project Team
- Designed for Direct Access to:
- Metrology
- Tooling
- Manufacturing
- Immediate Feedback
- Real Time Tool Adjustments
- Reduced Time to Market
Quality
IQ OQ PQ & PPAP Validation
PTI’s advance precision inspection and test abilities address a spectrum of dimensional and functional product specifications and requirements. Our capabilities support comprehensive inspection actions ranging from:
- Receiving to Final Audit
- First Article Layouts
- Full AIAG
Quality
Laboratory Services
Dimensional Inspection
- Direct Computer Controlled (DCC) CMM
- Including Optical and Video Capability
- Multi-Part Optical Measurement – Keyence Systems
- Traditional Metrology Inspection Tools
Mechanical Testing
- Tensile and Compression
- Torque
- Hardness (Rockwell and Durometer)
- Stress Relief Analysis
- Surface: Finish – Grain – Gloss
- Color and Hue: Color Match & Variation
- Leak (Air) and Water Emersion
- Managed CT Scan Services
Quality
System Standards
Certifications
- ISO9001 (General)
- ISO13485 (Medical)
- 21CFR part 820 (Health & Human Services)
- FDA Registered (Medical Device)
- MedAccred AC8160 Certifications for Plastics (Injection Molding and Mechanical Assembly)
- IMDS/Reach/RoHS (International Material Data System, Restricted or Hazardous Substances)
- MIL-STD-1916 (Military Test Method Standards)
- 22CFR part 120-122 (International Traffics in Arms Regulations)
Our Mission
Our Mission
- To provide exceptional solutions for our customers
- To be a supplier partner of choice
- To build an innovative and well-educated manufacturing team
- To embrace and implement new technology
- To maintain profitability, supporting the mission
DFM GUIDE
DESIGN FOR MANUFACTURING
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DFM Tool
Mold Design is a crucial step in the injection molding process. Once you’ve finalized your part in CAD software for fit and function, it must then be transformed into a design for molding to ensure the capture of all the specified details. In some cases, certain features of the part design may not be manufacturable via the injection molding process.At PTI, we collaborate with you to achieve the best possible design for manufacturability
Material Selection
Material Selection GuideThis selection guide is intended to help you determine the material candidates of your particular application. You’ll be able to quickly assess a number of factors, such as cost, heat resistance, strength and formability; then apply those findings to your project brief.
Compare material costs and temperature tolerances
Primary Design Considerations
TRANSITIONS, RADII, SINK AND WARPPlastics parts should be designed with uniform thickness whenever possible. If not possible due to design restraints, the transitions should be gradual, not abrupt. Variable thickness leads to uneven cooling and shrinkage of the plastics which leads to the potential of warp.
- Steps in the plastic create shear and turbulence.
- Relieve the outside radii if you need a hard outside corner.
- Sink will occur on the thick vertical wall connecting the two horizontal thinner walls.
- Long unsupported walls will tend to curl inward unless strengthening ribs are added.
DRAFT, PARTING LINES & UNDERCUTSAll parts must have draft on them to allow the part to be demolded. Parting lines must be taken into consideration when designing your part because they can have a dramatic effect on your design if not thought out; especially if your part requires a texture. Undercuts will also need draft in the draw direction of the action needed to form it.
Most applications can use 0.5° at a minimum, but draft angles of 1.5° per side are standard. A minimum of 2° draft angle is required for any surface that requires texture.
Primary Design Considerations
RIBSRibs and bosses can cause read through on visual surfaces if not designed properly. Rib thickness designs for different applications are illustrated below. For aesthetic surfaces, assure the rib thickness does not exceed 40% of the wall stock “T.” For less aesthetic importance, a rib thickness of over 60% of the nominal wall section “T” is acceptable.
T= Nominal Wall Thickness t =Rib Thickness
Design for appearance
Design for structure / non-appearance surfaces
Replacing thick parts with a ribbed structure reduces weight while adding strength.
Recommendations for rib dimensions
Source: DSM
Base ThicknessHeight Corner Radius Draft AngleSpacing
t≤0.5Th≤3T r≥0.25-0.5T ø≥0.5°S≥2T
BOSSESBoss designs have a lot of variation to them, depending on their function. They could be designed for threaded inserts, or as screw bosses or even for appearance. When designing bosses into your part, take into consideration the location in proximity to any wall. As illustrated below, you do not want to create a mass of plastic between the boss and the nearest wall. You should keep the same rib to wall stock ratio as described on the rib page.
T= Nominal Wall Thickness t =Rib Thickness
Boss Design Blue = Good Red = Bad
The thickness of the wall on a boss should be 40% - 60% of the nominal wall thickness of the part wall.
Primary Design Considerations
LIVING HINGESA restriction to the melt flow that will orient the molecules in the polymer across the hinge is critical when designing the thickness of the hinge. Thicknesses of .015” for polyolefins have shown to be optimal throughout the industry.
Source: Handbook of Plastics Materials and Technology Irvin I Rubin, Editor
FORMED THREADSDesigning threads on your part can be tricky. Make sure you consider how the thread starts and how it stops to make sure that it is moldable. A typical, true screw thread is not moldable as is because of the helix. The threads must be adjusted to be molded. It can be designed to be open to just a cavity and core movement, or made to have four actions forming the threads – all pulling 90 degrees to each other. One alternative is to add flats to allow the normally die-locked area of the threads to be open to die draw.
Assembly
SNAP FEATURESDifferent variations of snap features.
- Requires an action to form the detail. The amount of interference is dependent upon the plastic material being used.
- Requires no action, but it does create a hole through the part.
- May be made with no actions, but is draft and material dependent.
- Requires a collapsing core in order to be formed, is typically for larger parts and often more costly to manufacture.
BOSSES - PRESS FIT
Hex Press-FitHex pin and round hole boss. The points of the hex will be the interference and is easily adjustable in the mold if you start small.
Cross Rib Press-FitCross rib boss and round boss hole. This uses less material to be formed than the hex boss, but requires a more precise fit. You are hitting on the rounds of the boss rather than the points – thus causing more surface friction.
Crush Darts Press-FitCrush darts and the round hole boss. Crush darts are the easiest to crush and easily adjustable in the mold if you start small.
Assembly
BOSS DESIGNBosses are dependent upon the material selection. These charts illustrate a few examples.
Note: Refer to specific insert manufacturer's recommended design guidelines for your selected insert style.
Bonding
BONDING - ADHESIVE Various styles of adhesive bonding joints.
- The large arrow indicates the load direction to help prevent joints from peeling apart.
- Indicates a number of basic types of adhesive joint bonding designs.
SPIN WELDINGThe interference is what melts and holds the parts together. The amount of interference is material dependent. All good spin welding designs should incorporate a flash trap. The flash trap is a feature to capture displaced material during the welding process.
Bonding
BONDING - ULTRASONIC WELDING Ultrasonic welding or jointing uses interference to melt and hold adjoining parts together. The amount of interference is material dependent.
- In this design, flash from the displaced material is forced towards the inside of the part.
- Tongue and groove joints are helpful in containing flash while providing alignment.
- A chisel energy director can help prevent the displaced material from flowing into an opening.
- Some more difficult resins require a compressible path design using O-rings for a hermetic seal.
- A flash trap is a feature to capture displaced material during the welding process.
Overmolding
OVERMOLDINGThere are many different variations for mechanically locking the overmold to a non-covalent bonding substrate (illustrated below), however, overmolding provides more design options when you have a covalent bond condition. Note: shut-off between the materials is critical; an area is needed to compress the substrate to keep the overmold from flashing. A mechanical lock is required for overmolding onto metal or a non-bonding plastic to retain part integrity.
MATERIAL BONDING CHARTNot all materials will have a covalent (chemical) bond to other plastic materials. This chart shows a variety of materials and whether they form a covalent bond or will need a mechanical locking design.
Overmolding
SURFACE MARKING AND DECORATIONThere are a number of options for branding and marking products, both molded or with secondary production. Deciding factors are often timing, budget and material moldability. Options include: Painting, IMD, IML, EMI Shielding, Hydro Graphics, Adhesive Labels, Laser Printing, Pad Printing, and Molding.
- A label recess area is ideal for keeping logos or text below the part surface, adding styling while reducing wear.
- This illustration shows raised and recessed text, molded directly into the part during production.
- Laser printing is the process of engraving a part. Color can not be specified for this process, as it is dependent on the material being used and any additives or colorants within that material. Typical results are black, gray or brown in color. This is a permanent process and can’t be removed without sanding the surface smooth.
- Pad Printing offers multiple color options, using single-color inks. It is commonly used on products with limited direct handling, as it has the potential to wear or be wiped away with cleaning solutions with extensive use.
PLASTIC SURFACING GUIDEThis chart shows the finish options for plastics. D3 is the easiest to achieve while an A1 is the most time consuming and costly option.
Note: Work with your supplier for recommended draft angles.
Our Manufacturing Guideline is structured to provide you with the resources that you need for all your plastic design projects. If you have further questions or would like more details on designing for manufacturing best practices, please contact any one of our PTI representatives and they’ll be happy to assist you. PTI is a leader in custom injection molding and manufacturing of plastic components and assemblies, specializing in low-volume production. We are a technology driven company with extensive capabilities in design, engineering, tooling, and low- to high-volume production with an array of secondary services. We are fully versed in IQ/OQ/PQ validation processes and provide ISO Class 8 Cleanroom molding, assembly, and packaging services. For more information on how we can help you with your product, contact PTI at teampti.com or call 586.263.5100
Press to learn more about the anatomy of a tool.
DESIGN FOR MANUFACTURINGThis reference guide was assembled for product designers and engineers, intended to reflect good practices.PTI shall not be responsible or liable for consequential or indirect loss or any damages related to this guide.
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Cavity Insert - defines the external shape, surface finish, and details of the molded plastic part. Cavity inserts are precision-manufactured to ensure dimensional accuracy and are typically made from hardened materials to withstand the rigors of repeated molding cycles. Their design and placement within the mold assembly directly influence the quality and consistency of the final molded products.
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Gate - the opening in the mold cavity where the molten plastic enters from the runner. It controls the flow of plastic into the cavity, influencing factors such as part quality, cycle time, and material usage. Gates come in various types, such as direct gates, edge gates, and hot runner gates, each chosen based on specific molding requirements.
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Waterline - the channels or passages within the mold tool that circulate water to regulate and control the temperature of the mold during the molding process. These waterlines help in maintaining consistent cooling and solidification of the molten plastic, ensuring uniform part quality and reducing cycle times.
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Core Insert - a removable component within the mold tool that creates the internal features or details of the molded part. It is typically placed inside the cavity of the mold and forms the inner shape of the molded product. Core inserts are crucial for producing intricate designs, undercuts, or complex geometries in the final plastic part. They allow for flexibility in mold design by enabling different core inserts to be used interchangeably for varying product configurations without altering the entire mold structure.
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Slide - a movable component within the mold that allows for the creation of complex features or undercuts in the molded part. Slides are typically operated using hydraulic or mechanical systems and are designed to move perpendicular to the direction of the mold opening and closing. They enable the mold to produce parts with intricate geometries that cannot be formed with simple, straight-pull molds. Slides are critical for achieving detailed and precise plastic components in injection molding processes.
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Manifold System - a network of channels that distribute the molten plastic evenly to multiple cavities within the mold, ensuring consistent flow and temperature across all parts. It is a crucial component in hot runner systems, enhancing efficiency and reducing waste.
Ejector Plate - a critical component of the mold assembly responsible for housing and actuating ejector pins. It is typically located on the moving half (or ejector half) of the mold and serves the purpose of pushing the molded parts out of the mold cavity during the ejection phase. The ejector plate is designed to accommodate multiple ejector pins in precise configurations that align with the part geometry, ensuring even and controlled ejection. It plays a crucial role in the overall efficiency and reliability of the injection molding process by facilitating the smooth release of molded parts without causing damage or deformation.
Gib - a mechanical component used to adjust the clearance or fit between two mating parts of the mold assembly. Typically made from hardened steel or another durable material, gibs are often found in sliding mechanisms such as ejector systems or core pulls. Their primary function is to maintain precise alignment and allow for controlled movement within the mold, ensuring smooth operation and accurate production of molded parts.
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Support Pillar - a structural component that provides vertical support and guidance for the movable parts of the mold assembly. These pillars typically consist of hardened steel or another durable material and are strategically placed to maintain precise alignment and stability within the mold. Support pillars ensure that mold components, such as the movable platen or ejector system, operate smoothly and accurately during the molding process. They play a crucial role in maintaining the structural integrity of the mold and achieving consistent production of high-quality plastic parts.
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Cylinder Pull - the mechanical action of retracting or pulling back hydraulic or pneumatic cylinders within the mold assembly. This movement is crucial for various mold functions such as opening and closing the mold halves, ejecting molded parts, or actuating core pulls. Cylinder pulls are essential for precise and efficient operation of the mold, ensuring consistent production of high-quality plastic components.
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“B" Plate (Core) - This forms part of the mold assembly and typically houses the core inserts or cores. Cores are used to create internal features or cavities within the molded plastic part. The B plate provides structural support and alignment for the cores, ensuring precise molding of intricate details and geometries. It is essential for maintaining dimensional accuracy and ensuring the quality of the final molded products.
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Heel Block - a structural component within the mold assembly that provides support and alignment for the ejector system. It serves as a base where ejector plates or pins are mounted, facilitating their smooth and controlled movement during the ejection phase. Typically made from durable materials like hardened steel, the heel block ensures reliable operation and longevity in the mold’s production cycle.
Pin Plate - a specialized component of the mold assembly that contains and organizes numerous ejector pins. These pins are arranged in specific patterns and configurations on the pin plate, corresponding to the shape and requirements of the molded part. The pin plate is securely mounted within the mold and acts as a mechanism for ejecting the molded part from the cavity during the mold opening phase. It facilitates efficient ejection and helps ensure that the molded parts are released without damage, contributing to the overall productivity and quality of the injection molding process.
Hydraulic Cylinder - a crucial component that operates within the molding machine to exert force and pressure necessary for various mechanical functions. It uses hydraulic fluid under pressure to drive the movement of the injection unit, clamping unit, and ejector system during the molding cycle. Hydraulic cylinders are responsible for key actions such as injecting molten plastic into the mold cavity, clamping the mold halves together with force, and ejecting the finished parts from the mold after cooling. They provide the power and precision required for efficient and reliable operation of the injection molding process.
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Runner - the channel or pathway through which molten plastic flows from the sprue or nozzle into the cavities of the mold. It serves to distribute the plastic evenly to multiple parts within the mold and is typically removed from the final product during post-processing.
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Bottom Clamp Plate - a foundational component of the mold assembly situated on the stationary half of the mold. Its primary function is to secure and stabilize the mold during the injection molding process. The bottom clamp plate typically houses alignment pins or guide posts that ensure proper alignment between the stationary and movable mold halves. This alignment is crucial for maintaining the accuracy and consistency of the molded parts. Additionally, the bottom clamp plate provides structural support to withstand the clamping force exerted by the injection molding machine during mold closure, ensuring reliable operation and consistent part quality.
Ejector Pin - a mechanical component used to forcefully eject the molded part from the mold cavity once the plastic has cooled and solidified. Typically, multiple ejector pins are strategically placed within the mold to ensure even and controlled ejection of the part. These pins are actuated either hydraulically, pneumatically, or mechanically, pushing the finished part out of the mold cavity during the mold opening phase. Ejector pins are essential for facilitating efficient production cycles and ensuring the timely release of molded parts without damaging them.
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Hot Drops - components in a hot runner system that deliver molten plastic directly to individual mold cavities, maintaining the plastic at a consistent temperature to ensure uniform filling and reduce cycle times. They eliminate the need for runners, reducing material waste and improving the quality of the molded parts.
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“A” plate (cavity) - the part of the mold where the molten plastic is injected to form the desired shape of the product. The cavity, formed by the core and cavity plates, defines the external shape of the molded part and is crucial for achieving precise dimensions and surface finish.
“B” Backup Plate (Core Support) - a component that provides structural stability and support to the cores or core inserts within the mold assembly. It is typically located behind the core inserts or cores and helps to prevent deformation or movement during the molding process. The backup plate ensures that the cores remain securely in place, maintaining the integrity of the mold cavity and allowing for consistent and accurate molding of the plastic parts. It plays a critical role in achieving precise dimensional control and high-quality finished products in injection molding operations.
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Return Pins - mechanical components used to facilitate the movement and positioning of movable parts within the mold tooling system. These pins are typically spring-loaded and are designed to retract or return to their original position after being actuated. Return pins are often used in the ejector system to push the molded parts out of the mold cavity once they have solidified. They help ensure smooth and efficient ejection of parts from the mold, contributing to faster cycle times and improved productivity in injection molding operations.
Rail - guide rods that provide structural support and alignment for the moving components of the mold tooling system. These rails are often used in conjunction with other components such as the ejector system or the moving platen to ensure smooth and precise movement during the molding process. The design and maintenance of guide rails are crucial for achieving consistent part quality, minimizing mold wear, and optimizing the efficiency of injection molding processes.
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PTI Engineered Plastics Company Overview
Macomb, MI - 165,000 sqft
About Us
- Our superior design, tooling operations and manufacturing systems ensure that your finished product exceeds your expectations.
This resource is designed to help you learn more about the wide range of services and capabilities offered by PTI Engineered Plastics. Feel free to explore this resource to see how PTI can be your single-source solution from advanced product development to production manufacturing!PTI Engineered Plastics Virtual Tour
Virtual Tour Join us on a virtual tour of PTI Engineered Plastics, where we showcase our state-of-the-art facility and manufacturing capabilities. From design and engineering to custom molding and assembly, our team is dedicated to providing high-quality plastic components for a diverse range of industries. Get a behind-the-scenes look at our cutting-edge technology and processes, and see why we're a leader in plastic injection molding.
Our Services
For 40+ years, PTI has been your single source solution for plastic injection molding, manufacturing, product development, production, and assembly.
Design
Engineering
Tooling
Manufacturing
Automation
Value Add
Quality
Validation
Markets Served
PTI Engineered Plastics provides unparrelled services to the following markets:
Design
Product Development
We take great ideas and design them into manufacturable productsWhether injecting creativity into a current project or spearheading an entirely new product design, we seamlessly provide the path from an idea to reality — From mind to manufacturing.
Engineering
Engineered for Manufacturability
Design for ManufacturingEarly customer involvement in the Design for Manufacturing phase offers cost savings in product design and reduces lead time.Commercial Engineering Cost Estimators evaluate your product requirements to provide you with quotes that address every aspect of your project scope.Program ManagementA dedicated engineering team manages your project from design reviews to the delivery of precise parts. Quality EngineersOur quality engineers are well versed in IQ /OQ / PQ and PPAP requirements.Process EngineersOur process engineers are RJG certified Master Molders and utilize scientific injection molding principles to establish all nominal molding parameters.
Tooling
Quick to Market
PTI has built its reputation and success on the ability to get their customers’ products to market quickly and efficiently – without compromising mold design, part design, or quality.Functional Injection Molded PartsVertical integration allows us to quickly deliver adaptable, tooled parts for proof of concept.Alternate Material RunsAbility to evaluate multiple materials within the same set up.Bridge ToolingFunctional prototype tools are designed with production in mind and often used as bridge tools for early production runs. Rapid PrototypingFDM, SLA, SLS and Urethane Parts
Tooling
Built to Precision
On our Toolroom floor you’ll find a fully integrated tooling network comprised of mold designers and CNC programmers utilizing state-of-the-art software for our high-speed CNC vertical machining centers complimented by our plunge and wire EDM Machines. Toolroom
- 350 Tools Produced Yearly on Average
- Complete In-House Design
- Moldflow Analysis
High Speed CNC Machining- Horizontal 4 Axis
- 3 & 5 Axis
EDMTooling
Tooling Capabilities
Complex tooling and molds are where we specialize.At PTI, we use an array of materials from aluminum, mild steel, hardened steels, stainless and copper beryllium to create prototypes, low volume, hybrid and production tooling. Materials
- Aluminum | QC-10
- Mild Steel | P.20, NAK 55
- Hardened Steel | S-7, H.13, D.2
- Stainless Steel
Mold Bases- SPI Classifications | 101, 102, 103, and 104
Runner Systems- Cold Runner
- Hot Drop and Hot Manifold Systems with Valve Gate Options
Asset ManagementManufacturing
Technology Driven
Core Capabilities
Manufacturing
High Temperature Molding
One of Our Specialized ServicesHigh-temperature plastic injection molding is a specialized process used to shape heat-resistant polymers into precise parts. These polymers are ideal for extreme environments, where standard plastics would fail. The materials molded using this process offer enhanced thermal, chemical, and mechanical properties that ensure durability and performance.PTI Adheres to Strict Injection Molding Safety Guidelines
- Resin Temperatures as High as 850°
- High-Pressure Water to Accurately Maintain Mold Temperatures as High as 365°
- Flexible Automation for Safety and Repeatability
Materials – Our Wide Range of Engineered Grade Resins Include:Manufacturing
Controlled Environments
Our 10,000 sqft. Class 8 Cleanroom provides manufacturers with an optimal environment to produce and package medical and/or other devices under strictly monitored and controlled conditions. A certified Class 8 Cleanroom is designed to eliminate external dust, volatile emissions and other contamination agents that could endanger the health of a patient. Cleanroom
Automation
Precision Repeated
In today’s manufacturing environment, automation is essential to staying ahead of this ever-evolving industry. At PTI, we embrace this reality and actively integrate automation into our processes and operations. Below are some of the keyways we leverage the competitive advantages of automation here at PTI. Featuring
Value Add
Precision Repeated
When your project requires more, PTI offers many value added services to add those finishing touches. Assembly
- Component Assemblies & Subassemblies
Plastic Joining Assembly Process- Ultrasonic Welding
- Spin Welding
- Heat Staking
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DFM GUIDE
DESIGN FOR MANUFACTURING
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DFM Tool
Mold Design is a crucial step in the injection molding process. Once you’ve finalized your part in CAD software for fit and function, it must then be transformed into a design for molding to ensure the capture of all the specified details. In some cases, certain features of the part design may not be manufacturable via the injection molding process.At PTI, we collaborate with you to achieve the best possible design for manufacturability
Material Selection
Material Selection GuideThis selection guide is intended to help you determine the material candidates of your particular application. You’ll be able to quickly assess a number of factors, such as cost, heat resistance, strength and formability; then apply those findings to your project brief.
Compare material costs and temperature tolerances
Primary Design Considerations
TRANSITIONS, RADII, SINK AND WARPPlastics parts should be designed with uniform thickness whenever possible. If not possible due to design restraints, the transitions should be gradual, not abrupt. Variable thickness leads to uneven cooling and shrinkage of the plastics which leads to the potential of warp.
DRAFT, PARTING LINES & UNDERCUTSAll parts must have draft on them to allow the part to be demolded. Parting lines must be taken into consideration when designing your part because they can have a dramatic effect on your design if not thought out; especially if your part requires a texture. Undercuts will also need draft in the draw direction of the action needed to form it.
Most applications can use 0.5° at a minimum, but draft angles of 1.5° per side are standard. A minimum of 2° draft angle is required for any surface that requires texture.
Primary Design Considerations
RIBSRibs and bosses can cause read through on visual surfaces if not designed properly. Rib thickness designs for different applications are illustrated below. For aesthetic surfaces, assure the rib thickness does not exceed 40% of the wall stock “T.” For less aesthetic importance, a rib thickness of over 60% of the nominal wall section “T” is acceptable.
T= Nominal Wall Thickness t =Rib Thickness
Design for appearance
Design for structure / non-appearance surfaces
Replacing thick parts with a ribbed structure reduces weight while adding strength.
Recommendations for rib dimensions
Source: DSM
Base ThicknessHeight Corner Radius Draft AngleSpacing
t≤0.5Th≤3T r≥0.25-0.5T ø≥0.5°S≥2T
BOSSESBoss designs have a lot of variation to them, depending on their function. They could be designed for threaded inserts, or as screw bosses or even for appearance. When designing bosses into your part, take into consideration the location in proximity to any wall. As illustrated below, you do not want to create a mass of plastic between the boss and the nearest wall. You should keep the same rib to wall stock ratio as described on the rib page.
T= Nominal Wall Thickness t =Rib Thickness
Boss Design Blue = Good Red = Bad
The thickness of the wall on a boss should be 40% - 60% of the nominal wall thickness of the part wall.
Primary Design Considerations
LIVING HINGESA restriction to the melt flow that will orient the molecules in the polymer across the hinge is critical when designing the thickness of the hinge. Thicknesses of .015” for polyolefins have shown to be optimal throughout the industry.
Source: Handbook of Plastics Materials and Technology Irvin I Rubin, Editor
FORMED THREADSDesigning threads on your part can be tricky. Make sure you consider how the thread starts and how it stops to make sure that it is moldable. A typical, true screw thread is not moldable as is because of the helix. The threads must be adjusted to be molded. It can be designed to be open to just a cavity and core movement, or made to have four actions forming the threads – all pulling 90 degrees to each other. One alternative is to add flats to allow the normally die-locked area of the threads to be open to die draw.
Assembly
SNAP FEATURESDifferent variations of snap features.
BOSSES - PRESS FIT
Hex Press-FitHex pin and round hole boss. The points of the hex will be the interference and is easily adjustable in the mold if you start small.
Cross Rib Press-FitCross rib boss and round boss hole. This uses less material to be formed than the hex boss, but requires a more precise fit. You are hitting on the rounds of the boss rather than the points – thus causing more surface friction.
Crush Darts Press-FitCrush darts and the round hole boss. Crush darts are the easiest to crush and easily adjustable in the mold if you start small.
Assembly
BOSS DESIGNBosses are dependent upon the material selection. These charts illustrate a few examples.
Note: Refer to specific insert manufacturer's recommended design guidelines for your selected insert style.
Bonding
BONDING - ADHESIVE Various styles of adhesive bonding joints.
SPIN WELDINGThe interference is what melts and holds the parts together. The amount of interference is material dependent. All good spin welding designs should incorporate a flash trap. The flash trap is a feature to capture displaced material during the welding process.
Bonding
BONDING - ULTRASONIC WELDING Ultrasonic welding or jointing uses interference to melt and hold adjoining parts together. The amount of interference is material dependent.
Overmolding
OVERMOLDINGThere are many different variations for mechanically locking the overmold to a non-covalent bonding substrate (illustrated below), however, overmolding provides more design options when you have a covalent bond condition. Note: shut-off between the materials is critical; an area is needed to compress the substrate to keep the overmold from flashing. A mechanical lock is required for overmolding onto metal or a non-bonding plastic to retain part integrity.
MATERIAL BONDING CHARTNot all materials will have a covalent (chemical) bond to other plastic materials. This chart shows a variety of materials and whether they form a covalent bond or will need a mechanical locking design.
Overmolding
SURFACE MARKING AND DECORATIONThere are a number of options for branding and marking products, both molded or with secondary production. Deciding factors are often timing, budget and material moldability. Options include: Painting, IMD, IML, EMI Shielding, Hydro Graphics, Adhesive Labels, Laser Printing, Pad Printing, and Molding.
PLASTIC SURFACING GUIDEThis chart shows the finish options for plastics. D3 is the easiest to achieve while an A1 is the most time consuming and costly option.
Note: Work with your supplier for recommended draft angles.
Our Manufacturing Guideline is structured to provide you with the resources that you need for all your plastic design projects. If you have further questions or would like more details on designing for manufacturing best practices, please contact any one of our PTI representatives and they’ll be happy to assist you. PTI is a leader in custom injection molding and manufacturing of plastic components and assemblies, specializing in low-volume production. We are a technology driven company with extensive capabilities in design, engineering, tooling, and low- to high-volume production with an array of secondary services. We are fully versed in IQ/OQ/PQ validation processes and provide ISO Class 8 Cleanroom molding, assembly, and packaging services. For more information on how we can help you with your product, contact PTI at teampti.com or call 586.263.5100
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DESIGN FOR MANUFACTURINGThis reference guide was assembled for product designers and engineers, intended to reflect good practices.PTI shall not be responsible or liable for consequential or indirect loss or any damages related to this guide.
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Cavity Insert - defines the external shape, surface finish, and details of the molded plastic part. Cavity inserts are precision-manufactured to ensure dimensional accuracy and are typically made from hardened materials to withstand the rigors of repeated molding cycles. Their design and placement within the mold assembly directly influence the quality and consistency of the final molded products.
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Gate - the opening in the mold cavity where the molten plastic enters from the runner. It controls the flow of plastic into the cavity, influencing factors such as part quality, cycle time, and material usage. Gates come in various types, such as direct gates, edge gates, and hot runner gates, each chosen based on specific molding requirements.
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Waterline - the channels or passages within the mold tool that circulate water to regulate and control the temperature of the mold during the molding process. These waterlines help in maintaining consistent cooling and solidification of the molten plastic, ensuring uniform part quality and reducing cycle times.
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Core Insert - a removable component within the mold tool that creates the internal features or details of the molded part. It is typically placed inside the cavity of the mold and forms the inner shape of the molded product. Core inserts are crucial for producing intricate designs, undercuts, or complex geometries in the final plastic part. They allow for flexibility in mold design by enabling different core inserts to be used interchangeably for varying product configurations without altering the entire mold structure.
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Slide - a movable component within the mold that allows for the creation of complex features or undercuts in the molded part. Slides are typically operated using hydraulic or mechanical systems and are designed to move perpendicular to the direction of the mold opening and closing. They enable the mold to produce parts with intricate geometries that cannot be formed with simple, straight-pull molds. Slides are critical for achieving detailed and precise plastic components in injection molding processes.
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Manifold System - a network of channels that distribute the molten plastic evenly to multiple cavities within the mold, ensuring consistent flow and temperature across all parts. It is a crucial component in hot runner systems, enhancing efficiency and reducing waste.
Ejector Plate - a critical component of the mold assembly responsible for housing and actuating ejector pins. It is typically located on the moving half (or ejector half) of the mold and serves the purpose of pushing the molded parts out of the mold cavity during the ejection phase. The ejector plate is designed to accommodate multiple ejector pins in precise configurations that align with the part geometry, ensuring even and controlled ejection. It plays a crucial role in the overall efficiency and reliability of the injection molding process by facilitating the smooth release of molded parts without causing damage or deformation.
Gib - a mechanical component used to adjust the clearance or fit between two mating parts of the mold assembly. Typically made from hardened steel or another durable material, gibs are often found in sliding mechanisms such as ejector systems or core pulls. Their primary function is to maintain precise alignment and allow for controlled movement within the mold, ensuring smooth operation and accurate production of molded parts.
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Support Pillar - a structural component that provides vertical support and guidance for the movable parts of the mold assembly. These pillars typically consist of hardened steel or another durable material and are strategically placed to maintain precise alignment and stability within the mold. Support pillars ensure that mold components, such as the movable platen or ejector system, operate smoothly and accurately during the molding process. They play a crucial role in maintaining the structural integrity of the mold and achieving consistent production of high-quality plastic parts.
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Cylinder Pull - the mechanical action of retracting or pulling back hydraulic or pneumatic cylinders within the mold assembly. This movement is crucial for various mold functions such as opening and closing the mold halves, ejecting molded parts, or actuating core pulls. Cylinder pulls are essential for precise and efficient operation of the mold, ensuring consistent production of high-quality plastic components.
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“B" Plate (Core) - This forms part of the mold assembly and typically houses the core inserts or cores. Cores are used to create internal features or cavities within the molded plastic part. The B plate provides structural support and alignment for the cores, ensuring precise molding of intricate details and geometries. It is essential for maintaining dimensional accuracy and ensuring the quality of the final molded products.
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Heel Block - a structural component within the mold assembly that provides support and alignment for the ejector system. It serves as a base where ejector plates or pins are mounted, facilitating their smooth and controlled movement during the ejection phase. Typically made from durable materials like hardened steel, the heel block ensures reliable operation and longevity in the mold’s production cycle.
Pin Plate - a specialized component of the mold assembly that contains and organizes numerous ejector pins. These pins are arranged in specific patterns and configurations on the pin plate, corresponding to the shape and requirements of the molded part. The pin plate is securely mounted within the mold and acts as a mechanism for ejecting the molded part from the cavity during the mold opening phase. It facilitates efficient ejection and helps ensure that the molded parts are released without damage, contributing to the overall productivity and quality of the injection molding process.
Hydraulic Cylinder - a crucial component that operates within the molding machine to exert force and pressure necessary for various mechanical functions. It uses hydraulic fluid under pressure to drive the movement of the injection unit, clamping unit, and ejector system during the molding cycle. Hydraulic cylinders are responsible for key actions such as injecting molten plastic into the mold cavity, clamping the mold halves together with force, and ejecting the finished parts from the mold after cooling. They provide the power and precision required for efficient and reliable operation of the injection molding process.
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Runner - the channel or pathway through which molten plastic flows from the sprue or nozzle into the cavities of the mold. It serves to distribute the plastic evenly to multiple parts within the mold and is typically removed from the final product during post-processing.
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Bottom Clamp Plate - a foundational component of the mold assembly situated on the stationary half of the mold. Its primary function is to secure and stabilize the mold during the injection molding process. The bottom clamp plate typically houses alignment pins or guide posts that ensure proper alignment between the stationary and movable mold halves. This alignment is crucial for maintaining the accuracy and consistency of the molded parts. Additionally, the bottom clamp plate provides structural support to withstand the clamping force exerted by the injection molding machine during mold closure, ensuring reliable operation and consistent part quality.
Ejector Pin - a mechanical component used to forcefully eject the molded part from the mold cavity once the plastic has cooled and solidified. Typically, multiple ejector pins are strategically placed within the mold to ensure even and controlled ejection of the part. These pins are actuated either hydraulically, pneumatically, or mechanically, pushing the finished part out of the mold cavity during the mold opening phase. Ejector pins are essential for facilitating efficient production cycles and ensuring the timely release of molded parts without damaging them.
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Hot Drops - components in a hot runner system that deliver molten plastic directly to individual mold cavities, maintaining the plastic at a consistent temperature to ensure uniform filling and reduce cycle times. They eliminate the need for runners, reducing material waste and improving the quality of the molded parts.
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“A” plate (cavity) - the part of the mold where the molten plastic is injected to form the desired shape of the product. The cavity, formed by the core and cavity plates, defines the external shape of the molded part and is crucial for achieving precise dimensions and surface finish.
“B” Backup Plate (Core Support) - a component that provides structural stability and support to the cores or core inserts within the mold assembly. It is typically located behind the core inserts or cores and helps to prevent deformation or movement during the molding process. The backup plate ensures that the cores remain securely in place, maintaining the integrity of the mold cavity and allowing for consistent and accurate molding of the plastic parts. It plays a critical role in achieving precise dimensional control and high-quality finished products in injection molding operations.
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Return Pins - mechanical components used to facilitate the movement and positioning of movable parts within the mold tooling system. These pins are typically spring-loaded and are designed to retract or return to their original position after being actuated. Return pins are often used in the ejector system to push the molded parts out of the mold cavity once they have solidified. They help ensure smooth and efficient ejection of parts from the mold, contributing to faster cycle times and improved productivity in injection molding operations.
Rail - guide rods that provide structural support and alignment for the moving components of the mold tooling system. These rails are often used in conjunction with other components such as the ejector system or the moving platen to ensure smooth and precise movement during the molding process. The design and maintenance of guide rails are crucial for achieving consistent part quality, minimizing mold wear, and optimizing the efficiency of injection molding processes.