Plastic Injection Molding
Progressive Plastics, Inc. is a forward-thinking, full-service plastic molding company committed to delivering high-quality, customized plastic solutions for a wide range of industries. Our innovative approach to plastic manufacturing is backed by decades of experience, advanced technology, and a dedication to continuous improvement that allows us to enhance the efficiency and precision of our processes.
We specialize in injection molding, including insert molding, a technique that allows us to mold plastic around metal or other non-plastic inserts, producing durable, multi-material components in a single process. This method is ideal for creating products that require threaded components, electrical connections, or added structural integrity, and it reduces assembly time and increases part reliability.
Progressive Plastics is equipped to handle production runs of all sizes—from short runs for prototyping or specialty items to high-volume production for large-scale distribution. Our scalable manufacturing capabilities ensure cost-effectiveness and consistency at every level of production, making us a trusted partner whether you're launching a new product or managing ongoing demand.
Additionally, we provide light assembly services to help streamline your supply chain. Our team can perform essential post-molding operations such as component integration, hardware installation, packaging, and labeling, allowing you to receive finished or semi-finished parts ready for final use or distribution. By offering assembly in-house, we help you reduce lead times, lower transportation costs, and ensure strict quality control throughout the entire process.
At Progressive Plastics, Inc., our mission is to be more than just a parts provider—we strive to be a value-added partner by optimizing processes, supporting product development, and delivering results that exceed expectations.
Progressive Plastics, Inc. For Products That Matter
Progressive Plastics, Inc. solves mission-critical needs to reduce supply chain risk and complexity. Our broad custom molding capabilities coupled with technical expertise allow us to bring forward-thinking solutions to your projects. With decades of injection molding experience, our accessible team provides a personalized commitment to your project from start to finish.
Injection Molding Capabilities
We mold solutions. Our strategically located Centers of Excellence offer dedicated expertise with over 100,000 square feet of space for precision injection molding, prototyping, plastic overmolding, insert molding and advanced tooling design and builds.
Progressive Plastics, Inc. believes early collaboration is critical to successful new product introductions. In working alongside our customers, our goal is to reduce product cost and time-to-market. We welcome the opportunity to discuss your next project or current production demands.
- Terminals/contacts
- Screw machine components
- Cold headed components
- Wound-coil bobbins
- Photo-etched components
- Magnetic compounds
- Small: 50,000 to 100,000 units
- Medium: 100,000 to 1 million units
- Lower Start-up Investment
- Faster Start-ups
- High: > 1 million units
- Cost reduction opportunities
- Secondary operations can be achieved (e.g. in molded terminals bends, circuitry cutouts)
- Reliability of operation
- Dimensional stability
- Lower scrap—approaching zero PPM
- Reduced inventory Part Count
- Feeder bowl – (loose component feeding)
- Continuous strip feeding
- Robotic pick and placement/retrieval
- Mechanical/electrical testing
- Vision System to ensure accurate insert placement
- Achieves an efficient and streamlined product design
- Reduces secondary operations, assembly and post-molding labor costs
- Improves part functionality and reliability by binding two plastic materials in one step
- Encapsulation of components can provides protection from corrosion, vibration and/or shock for environmentally-sensitive metals or electronic parts
- Polycarbonate (PC)
- Polyamide 6/66 (PA)
- Acrylonitrile Butadiene Styrene (ABS)
- Polypropylene (PP)
- PC/ABS blends
- Polyester (PE)
- Acetal (POM)
- Polybutylene Terephthalate (PBT)
- Polyphenylene sulfide (PPS)
- Polysulfone (PSU)
- Thermoplastic polyurethane (TPU)
- Thermoplastic Rubber (TPR)
- Reinforced grades
- Full- and semi-recess action
- Balanced tooth strength
- Maximum contact ratio
- Improved power efficiency
- Enhanced motion efficiency
- Precision fabrication to AGMA #9 standards
- High- or low-volume requirements
- Specialized tooling design
- Value-added features, including one-part molding
- Material selection using highly engineered resins
- Insert-molded gears
- In-house tool design
- On-site production and prototype tool fabrication
- Tool sourcing with reliable, cost-effective shops
- Real-Time Preventative Maintenance program
- On-site major mold repair shop
- A team of skilled craftsmen and knowledgeable mold builders
- Hot runner systems
- Unscrewing molds
- Inserting molds
- Family molds
- Auto-self degating robotic extraction
- Modular or master unit die (MUD) construction
Custom Insert Molding & Overmolding
PMT specializes in complex insert molding and overmolding. As a premier provider of complex plastic insert molding, we offer custom automation cells, advanced robotics, vertical injection and rotary table molding.
PMT knows the challenges of custom insert and overmolding requires a strategic partner who can be your guide—outline the course, map the process and ultimately arrive at the desired outcome, on time. Partnering with PMT means you can be confident you're getting the experience and engineering expertise to guide the process from start to finish.
Our experienced team can perfect your part design with a variety of materials—from plastics, elastomers and metals to aluminum, brass, steel, copper and more.
Insert Molding
PMT’s insert experience includes terminals and contacts, screw machine components, cold-headed components, wound-coil bobbins, photo-etched components, and magnetic compounds. Production capabilities include both manual and automated loading, using vertical, horizontal or rotary table presses. Automation capabilities include feeder bowl, continuous strip feeding, robotic pick and placement/retrieval, and mechanical and electrical testing. PMT also offers custom automation systems for insert molding, using advanced robotics.
Insert Types
Manual Insert Loading
Annual Volume
Benefits of Manual Loading
Automated Insert Loading
Annual Volume
Benefits of Automation
Types of Automation
Overmolding
PMT is a trusted overmolding source for customers in the electrical, medical device, appliance, telecommunications, transportation and electronics sectors. The overmolding process allows one thermoplastic materials to be molded over another material. The bonded materials create a single plastic part that achieves a particular aesthetic or ergonomic goal.
Materials are the focus of the overmolding process. With backgrounds and training in polymer science and plastics engineering, our expert team can help you navigate the complexities of resin selection to optimize the molding process for you part.
Benefits of Overmolding
Our experts will work with you to ensure your insert or over molding project will meet the most stringent quality standards. We welcome the opportunity to speak with you and discuss your next project or current production demands.
Solving Your Material Selection Challenges
Thermoplastic resin selection is critical to product performance and reliability. PMT's Engineering & Design team expertly guides customers through the material selection process to narrow in on the best options.
PMT has injection molding down to a science, and is experienced in guiding customers through the selection process to find the best plastic resin to achieve full part functionality—and project timelines.
At PMT, highly engineered resins are processed daily to meet the rigorous performance requirements of our customers and their end-customers. We also have extensive experience working with thermoplastic rubbers (TPR) and elastomers (TPE), which are widely used in automotive, electrical, medical and appliance applications. We work with engineering-grade filled and high-heat materials, and specialize in processing materials with high percentages of glass, carbon, talc or other reinforced fillers.
Some of the main engineering resins we mold include:
Along with bulk resins, PMT sources a variety of other materials, including compounded and master-batched resins, colorants, magnets, stamped metal components, machined metal inserts and packaging materials.
PMT maintains strong relationships with key manufacturers and distributors of materials used in our manufacturing processes. We are actively engaged with our key resin suppliers to ensure we can offer clients competitive pricing while reducing the risk of supply disruption.
With RoHS training and certification, our team can help you make the right decision but the best decision for your situation. We welcome the opportunity to speak with you and discuss your next project or current production demands.
Precision Plastic Gears and Moving Parts
Plastic Molding Technology manufactures precision gears, insert-molded gears and other functional parts to meet the highest technical and quality standards.
We can help design and engineer plastic gears for:
Our gear molding expertise includes:
Specialized quality assurance for gear molding
PMT's expert Quality team provides full layout gear inspection using the latest measuring and testing equipment. We offer full quality assurance programs tailored specifically for gear manufacturing as well as functional gear inspection. Our Quality Lab includes the VARI-ROLL™ Radial Dual Flank Composite Analyzer System for gear testing, and includes tools for calculating test radius and center distances using circular tooth thicknesses or dimensions over rolls.
Contact our team to learn more about our plastic gear molding capabilities.
Bring in the Experts
Let PMT guide your new product development to eliminate guesswork and create expertly-design plastic parts from the start with available 3-D printing, CNC machining and injection molding technologies.
Injection Mold Design, Build & Repair
PMT's Engineering & Design team takes your project from start to finish—on time. We streamline the manufacturing process into a one-stop shop experience with in-house mold design, building and repair.
PMT offers:
Decreasing Lead Times and Costs for Production Builds
Plastic Molding Technology’s mold-building and sourcing capabilities range from design and 3-D modeling to building or sourcing of high-precision injection molds. We offer prototype molds and high-volume production molds, including Class I warranted molds and Class 101 tooling with hardened steel cores and cavities.
We have made or sourced a variety of complex molds, including molds made by our trusted and proven business partners in the U.S. and Asia. Molds are designed and crafted to SPI/DIN standards.
Our mold expertise includes:
Our on-site, full-service tooling shop is fully equipped to maintain, repair, and modify molds. Customer tools are housed in our custom Stanley VIDMAR mold storage system. All tools have full traceability for preventative maintenance schedules, repairs, cycle counts and real-time production through the plant-wide IQMS ERP system.
Additional Capabilities
Product Development
Let our experienced engineers guide your next product development project to help reduce time-to-market while eliminating risk and complexity.
Engineering & Design Support
Our team of engineering professionals provides turnkey solutions of precision-engineered parts and components.
Finishing & Assembly
Progressive Plastics, Inc. provides turn-key finishing and assembly services across our four Centers of Excellence.
