Specialty Molding
Specialty Molding
(Offered through Foam Molders Inc.)
When standard options for parts are not sufficient for your needs, specialty molding combines sophisticated design and manufacturing capabilities to meet proprietary requirements. Working with our team at FMI, we can help you transform your vision into a tangible product that you can use for your desired application.
FMI utilizes reaction injection molding, casting and foam in place. We mold urethane elastomers, rigid, semi rigid, self skinning and flexible foam. Products range from fuel floats and bumpers, to spa cushions and parts for theme parks. We complete both small and large assemblies. Our attention to detail, competitive pricing and customer service distinguish us from our competitors. Because of the different applications and formulas, we are limited only by your imagination.
Why Use a Custom Molding Solution?
Our custom molding solutions enable you to create a variety of nonstandard, proprietary, or brand-specific parts for your business. We start with your design goals and specifications and reverse-engineer a solution using our advanced molding processes.
Once we’ve created the molds for your products, we are able to continuously manufacture new parts for you at scale. This helps save you time, expenses, and effort with the assurance that you can meet your production demands with us as your custom molding partner.
Custom molding is also a fantastic solution for creating parts that feature shapes for licensed properties. If you have a licensing agreement with a show, movie, or other popular production, we can create likenesses of shapes and characters associated with the property with immense attention to detail and materials that can be easily painted.
Processes
Knowing the proper forming and processing techniques helps in choosing one type of processing method over the other. Further classification of plastic materials or resins, can be used to choose the best technique to form a particular product. While completing both small and large assemblies, we utilize the following processes:
- R.I.M. (Reaction Injected Molding)
- Specialty molding
- Casting
- Custom assemblies
- Foam in place
- Molding of Urethane
- Custom foam molding
Post assemblies include:
- Screws
- Screws
- Brackets
- Electrical components
- Threaded inserts
Our raw material is qualified to:
- DMS 1957
- FAR 25.853
- DMS 2451
- BMS 8-350 type 1 & 2
Markets Served
The materials used in specialty molding processes create a versatile solution that can complement the parts needs of a variety of industries. From commercial to consumer applications, people encounter more custom-molded products in their daily lives than they might be aware of.
We serve numerous markets. Our products range from fuel floats and bumpers to spa cushions and parts for theme parks. Below are some of the industries represented. If you don’t see yours listed, give us a call. We are always interested in exploring new opportunities.
- Aeronautic
- Physical Fitness
- Entertainment
- Medical
Products / Applications
Our molded products are not easily recognized, but they are used in many applications on a daily basis. Our attention to detail, quick turnaround times, reasonable cost of molds and our commitment to customer service, helps us to keep you, our customer, our #1 priority.
Due to the versatility that custom molding provides, there are few limits to the applicability of our solutions. We frequently venture into providing solutions for new markets and industries to help create proprietary or specialized products for customers.
Tooling
Our talented staff will work with you to ensure that the proper tooling is created to produce your parts. Some molds are top filled and are made from aluminum, epoxy composite and silicone. Molds are made for all processes. Having this in-house capability allows us to save time and get your job into production in a timely manner. We can also store your tooling so it is always on hand for your projects. Please see some examples of tooling below.
- CNC Aluminum cavity w/ injector points (for R.I.M.)
- Exopy composite w/ injector points (for R.I.M.)
- CNC Aluminum top filled molds
- Epoxy top filled molds
- Silicone glove mold for complex parts with textured patterns
Case Studies
Below are a few examples of how we have worked with businesses in a variety of industries to produce completely custom solutions for their parts needs. From medical to entertainment, environmental applications, home improvement, and more, these case studies illustrate the true versatility that custom molding has to offer.
Bone growth stimulation
We get the opportunity to be involved with some interesting and life changing products. This client produces regeneration products which consist of bone growth stimulation devices that are used to treat non union fractures and as an adjunct therapy after spinal fusion surgery. This part requires electronic components to be embedded in it, along with several additional assemblies to complete this operation.
Head rests and cushions
We supply the entertainment industry with many parts. From elastomer covered aluminum pulley wheels, head rests, bumpers and simulated wood grain bench pads we do it all! You may not know our parts but you’ve probably used them at one time or another. So next time you take a ride it might be on us!
Environmentally friendly
FMS is proud to be associated with companies dedicated to preserving our environment. They manufacture an artificial tree that helps enhance the appearance of our highways and by ways. These trees are actually placed in with a group of palm trees and it is hard to pick them out. To get the realism needed, attention to detail is once again required. Every part goes through our QC department before it is passed on to a freeway near you!
Shower / bath transfer system
This company supplies unique products that serve the special needs of disabled children and adults. They had some unique requirements. Not only did it have to be bacteria and fungal resistant, but latex and silicone free. It also needed to be firm enough for repeated use and have some resiliency capabilities. We were able to come up with the formulations needed to match those needs.
Get Specialty Custom Molding for Your Business Today
With two facilities in Cerritos, CA, our team at FMI provides custom molding solutions to a global network of customers. All of our specialty parts are 100% U.S.-made and produced in-house by our expert team.
To learn more about how we can partner with you to create the custom-molded parts you need for your business, contact us today to learn more.
FAQs
Specialty molding involves creating complex or unique shapes and designs for products that cannot be produced through traditional molding techniques. Specialty molding requires specialized equipment and expertise and uses advanced materials and processes.
Specialty molding can use various materials, including plastics, metals, and composites. Depending on the application, materials may be chosen for their strength, flexibility, durability, or other properties. Some common materials used in specialty molding include thermoplastics, thermosets, rubber, silicone, and carbon fiber.
Specialty molding is used in numerous industries, including automotive, aerospace, medical, electronics, and consumer products. Applications can range from small, intricate components to large, structural parts. Specialty molding is often used when a product requires a unique shape, specific performance characteristics, or strict dimensional tolerances.
Specialty molding differs from traditional molding techniques because it requires specialized equipment and expertise. Conventional methods, such as injection molding, involve creating parts from a mold with a simple, uniform shape. On the other hand, specialty molding creates complex shapes and designs that require more advanced tooling and processing. Specialty molding may use multiple molds or advanced techniques, such as over-molding or insert molding.
Specialty molding offers several advantages over traditional molding techniques, including creating unique shapes and designs, producing high-precision parts with tight tolerances, and using advanced materials for improved performance. Specialty molding can reduce assembly costs by combining multiple elements into a single component and can improve part strength and durability by eliminating joints and seams.
When selecting a specialty molding provider, consider factors such as their expertise in your industry, their equipment and capabilities, their quality control processes, their ability to meet your production requirements, and their overall reputation and customer service. You may also consider factors such as pricing, lead times, and the ability to handle complex or unique projects.
To get started with specialty molding, you should research and select a reputable specialty molding provider with experience in your industry and the type of molding you require. You should provide detailed specifications for your part or component, including unique shapes or design requirements, and work closely with your provider throughout the process to meet your needs. Your provider may also offer advice and guidance on material selection, tooling design, and other factors affecting project success.