Molding Services

PROTOTYPING

The practice of prototyping, even Rapid Prototyping, comes in many forms. But in the plastic injection molding world of prototyping a product, only one process can take you directly to market. Most prototype processes are only able to provide moderately (semi) to non-functional, “touchy-feely” type models, or parts that require design and material intent modifications.

AIM designs, develops and manufactures prototype plastic injection molds at a quality and precision level that absolutely “does not require any changes” to a customer’s intended production design or material intent. In many cases, it can be used to satisfy production requirements.

AIM offers a collection of services that help provide customers with their fastest path to market:

• Design assistance which includes design for manufacturability
• Rapid Prototyping through the use of AIMFast Trac™
• Prototype-Plus™ - provides customers with the opportunity to utilize their prototype molds to satisfy early,short-run or, in many cases, their low volume production needs
• A modular option utilizing AIM’s ‘Master Mold Frame' system
• Prototype samples for testing and validation
• All required quality submissions are made available for prototypes and short-run parts

Dependent on the deliverable requirements of a project, several physical modeling processes of a design (limited or non-functional), are available in the marketplace that AIM can outsource and manage as a product development service for customers:

“Having a prototype that comes close to matching the final product is ideal.”
{quote from an article in National Instruments newsletter titled “Eight Rules for Prototyping” by John Hanks (Vice President of product marketing for data acquisition and industrial control at National Instruments), Publish Date: Nov 14, 2008}

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SHORT RUN MOLDING

By some, a loose industry definition of ‘short-run molding’ might be thought of as any run that lasts less than 48 hours (that includes setting up the mold and machine as well as tear-down times). Some have defined it as a one-time run of parts, not an annual production requirement. Others advertise that short-run molding is quantity based, offering runs in the tens of thousands of parts.

AIM has always, and will continue to let our customers' needs dictate what a short molding run consists of. AIM has successfully completed numerous projects ultimately requiring 1 part –1 time, to projects requiring frequent runs of thousands of parts per run.

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LOW VOLUME PRODUCTION

The question often asked by customers is “…what does AIM consider low-volume production?” AIM considers low-volume production as being any program requiring annual production volumes of as little as “1” piece per year, to volumes that can reach into the tens of thousands.

Successful low-volume production requires a unique business culture that differs greatly from high-volume manufacturing. AIM began and developed its business model in the prototype, short-run and low-volume production marketplace. Over the past two decades of challenging experiences, AIM has perfected a culture believed crucial to successfully quoting, managing and delivering on short-run, low-volume production products to virtually every manufacturing market segment.

AIM provides manufacturing solutions using its comprehensive list of capabilities and services to any and each level of product development and delivery, be it prototype, short-run, low and/or high volume production.

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HIGH VOLUME PRODUCTION

AIM’s Manufacturing Center, which houses a 6,000 square foot ISO Class 7 (10k) clean room, features a full complement of general molding capabilities, along with several advanced molding technologies, with a tonnage range of 22 to 440 tons. Combined with a comprehensive list of value added services, including assembly and packaging, AIM has the ability to support your high volume production needs.

High Volume Production Highlights:

• In-house product design assistance, tooling design and manufacturing
• Molding capacities of 22 ton to 440 ton
• 2-Shot, Micro-molding, Insert & Over-mold molding capabilities
• Scientific Molding utilizing the RJG process monitoring systems
• Full range of value-added secondary services

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CLEAN ROOM MOLDING AND ASSEMBLY

Thru our 6,000 square foot ISO Class 7 (10K) cleanroom, we are able to offer injection molding, product assembly, as well as process verification and validation services to meet your most challenging manufacturing needs.

AIM has the capability to manage programs requiring rapid prototyping/short-runs through high volume production of manufactured products for the healthcare industry. With over two decades of short-run,low-volume production experience, AIM has perfected the culture necessary to manage and successfully deliver on products designed for the ever-changing healthcare marketplace.

This clean room facility provides capabilities to mold products requiring conventional precision molding as well as insert,over-molding and 2-shot molding. Capacities ranging from 22 - 440 ton. In addition, AIM offers comprehensive assembly, assembly process validation, post-molding operations, and specialty services.

Capabilities Offered

• ISO Class 7 (10k) clean room manufacturing
• Comprehensive in-house tooling services
• Design and product development assistance
• Facilities operate under lean manufacturing principles
• Comprehensive range of value-added secondary services
• Conventional precision molding which includes - insert, over-molding and 2-shot molding
• Design and manufacturing with a wide range of standard and specialty engineered grade resins

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ADVANCED MOLDING TECHNOLOGIES

At AIM, we eagerly listen to the voices of our customers and industry to guide our continued research and investment in new ideas, services, and resources that will ensure unparalleled speed and support for our customers’ products and projects.

To support the prototype, short-run, low and high volume production molding challenges of our customers, AIM provides several advanced molding technologies:

• True rotary 2-shot molding
• Vertical insert molding with rotary platten
• Over-molding
• Micro-molding
• Scientific Molding

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