Scaling Up: From Basement Casting to Injection Molding Mastery

Having been in business for over 20 years, we’ve witnessed countless journeys in the world of injection molding. And we’ve taken great pride in partnering with entrepreneurs, turning their innovative ideas into tangible products.

One example involves a client who transformed their basement operation into a thriving business with Extreme Molding's help. In this case study, we’ll explore how outsourcing manufacturing helped him scale up from a casting production process to injection molding.

injection molding case study

The Challenge

Silicone casting is a great way for a passionate entrepreneur to get started making their own silicone products. It's low-cost, DIY-friendly, and perfect for handy individuals with a knack for research. This is exactly how our client began – churning out 20-50 parts a day in their basement with silicone casting.

It was a humble start, but as demand grew, production and supply couldn't keep up. Like most self-starters, he struggled to find time to sell his product and expand his offerings due to the constant demands of production. 

This is where our collaboration began. In fact, this is when most customers reach out to us – when they need expertise and resources to overcome these challenges. Whether it's navigating the complexities of retail launch, fixing a quality issue with their casting, or leveraging our vendor relationships and economies of scale to reduce material costs – we’re able to help them reach their full potential.

The Solution

When our entrepreneur decided it was time to outsource manufacturing, he turned to us for guidance. However, he was a little reluctant because he had worked with a different manufacturer in the past and was unhappy with the results. The previous manufacturer had used a different material to aid in injection and lower manufacturing costs. As a result, the material surface finish didn’t match and didn’t perform or feel the same. 

Armed with our coloring matching expertise, wide variety of material offerings, and knack for custom finishes, we tackled the challenge head-on. We knew that the key to success was in understanding the nuances of materials like TPE and silicone. (They can be purchased in the same Shore hardness, but their physical and mechanical properties are very different.) By leveraging our knowledge and capabilities, we delivered a superior solution.

The Result

The transition from basement casting to injection molding proved to be a game-changer. By working with Extreme Molding, our client's production skyrocketed from 20-50 parts a day to over 1,500 in a 24-hour period. We were able to fill up his inventory in a day’s worth of production that would’ve taken one month through casting.

Additionally, the quality, the material match, and the surface finish exceeded our client’s expectations. He even noted:

“The material match was exact. They nailed the critical dimensions on a complex shape. The tolerances they use are very tight and other vendors would not sign up for such tight tolerances of a complex shape with varying wall thicknesses. This is why they’re experts in silicone molding.”

He was so satisfied with our work that he returned to us for a second mold project. This cemented our partnership and highlighted the value of scaling up by outsourcing your manufacturing processes.

The Future

It's incredibly rewarding to collaborate with passionate entrepreneurs, navigate their challenges, and ultimately produce high-quality products that resonate with their target market. We've partnered across various industries, transforming prototypes into market-ready goods and turning small scale operations into full-fledged businesses through our expertise in materials and design. 

If you have a product that you need to produce, contact us today for a free consultation. We’re happy to see where we can help.

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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.

May 27, 2024 |