A Deep Dive into the Extreme Molding Manufacturing Process

Injection molding plans review by the Extreme Molding team

At Extreme Molding, we often get asked the question, “What makes you the number one silicone injection molder of consumer products in the USA?” The answer we give them is simple. We are unlike any other silicone products manufacturer. Our personal approach, full-service model, and proprietary manufacturing process are designed to ease the customer’s transition from prototype or foreign-made product to successful, made-in-the-USA product.

Our unique manufacturing process starts with a friendly and speedy response to a customer’s initial inquiry. From there, our full-service and manufacturing process begins.

Working with the Sales Team

  1. Evaluation

At Extreme Molding, we require CAD files of your product, to determine if your product is a good match for our in-house capabilities. After filling out our initial contact form, we will follow up with an email including a link to our secure server where you can upload your CAD files for us to review. Our preferred CAD file types are .STP/ .IGS / .X_T.

If requested, we can provide our mutual NDA to protect your intellectual property. Other things we like to know is your expected production volume, product sizing, and if your company has a sales and marketing system in place to help with production fulfillment.

  1. Estimation

After reviewing your CAD files, you can set up a conference call to discuss your product further. You can expect preliminary cost estimates within hours of this call, and final numbers in about two days after. Transparency is extremely important to us, so we will break down the cost of materials, labor, packaging, and overhead.

  1. Problem Solving

Our team of highly skilled engineers have vast experience in silicone materials and applications. They will consult with your team to design your product for large-volume manufacturability without compromising function or visual appeal.

  1. Material Selection

We are experts in a wide range of specialty silicones. The Extreme Molding team will work with you to select the right materials to meet your product’s performance, durability, safety, and regulatory requirements.

  1. Sourcing your Mold

We have a strong relationship with our mold-making partners, most of which are in New York State, and will be actively involved in the design process to ensure your mold meets our exacting standards. We ask for a down payment on the mold with the remaining balance due after mold arrival and first article approval.

  1. Package Design

Extreme Molding is unique among custom molders in the United States because we back up our expert production with packaging and global fulfillment of your high-end consumer or life science product. We direct you to sources to help you create specialized retail packaging to protect and showcase your product.

Working with the Quality Assurance Team

  1. First Article Approval

Once we have your mold in-house, we will produce parts for the first article approval and issue a report comparing your specifications to those of the molded components. Any issues will be addressed immediately and if all is well, we will move into full-scale production of your product.

Working with the Operations and Engineering Teams

  1. Production

At Extreme Molding we have over 50 team members working three shifts, five days a week. This allows for us to be flexible and responsive to your requests and we are accustomed to tight schedules.

  1. Secondary Operations and Assembly

We are prepared to perform secondary operations beyond molding so you can focus on inventing, marketing, and selling your product. We perform a wide range of secondary operations in-house, including:

  • Die-cutting
  • Assembly
  • Cryogenic Deflashing

Working with Packaging and Fulfillment

  1. Packaging and Fulfillment

Finished products will be thoroughly inspected, then packaged in our white-wall room and prepared for shipment to anywhere in the world. We ship to over 500 locations worldwide including Home Depot, Amazon, Walmart, Target, buybuyBaby, and more. We can also ship to individual customers directly.

We understand the importance of getting your product into your customer’s hands as quickly as possible. Shipments leave our location daily, via priority mail from the U.S. Postal Service, FedEx or UPS. In most cases, orders are shipped within 24 hours of receipt. You can be assured your customers will always receive the same high-level of customer service you receive as our partner.

Watch our video to learn more about our Packaging and Fulfillment Services
Have an idea for a product?

Do you have a great idea for a US manufactured product? We can help bring it to life. From advising you through the injection molding process, to delivering your new product to customers, we want to work with you every step of the way. Contact us to learn more.