The Extreme Molding Manufacturing Process

A partnership with Extreme Molding is unlike any other plastic and silicone products manufacturer. Our personal approach, full-service model and proprietary manufacturing process are designed to ease the transition from prototype or foreign-made product to successful, made-in-the-USA product.

Our process always starts with a quick, friendly reply to your first inquiry. From there, we will follow these steps:

Product Evaluation EVALUATION: We will require a CAD file to determine if your product is a match for our unique skill set. We are always happy to sign a non-disclosure agreement to protect your intellectual property.
Product Estimating ESTIMATION: You can expect preliminary cost estimates within hours of our first conference call, and final numbers in about two days. Transparency is important to us, so we will break down the cost of materials, labor, packaging and overhead and disclose our expected profit margin.
Problem Solving PROBLEM SOLVING: Our engineers will consult with your team to design your product for large-volume manufacturability without compromising function or visual appeal.
Material Selection MATERIAL SELECTION: We are experts in a wide range of specialty plastics and silicones, and will work with you to select the right materials to meet your product’s performance, durability, safety and regulatory requirements.
Sourcing a Design Mold 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. Expect six to eight weeks for mold construction. We ask that mold costs are paid 50 percent up front, with the balance due after first article’s approval.
Package Design PACKAGE DESIGN: We will direct you to our packaging design partners to create your custom retail packaging.
First Approval FIRST ARTICLE APPROVAL: Once we have your mold, we will produce parts for first article approval and issue a report comparing your specifications to those of the molded components. Any issues will be addressed immediately. If all is well we will move into full-scale production.
Silicone Production PRODUCTION: We have over 50 team members working three shifts, seven days a week. We are flexible, responsive to your requests and accustomed to tight schedules. Our minimum order requirements are quite reasonable.
Assembly SECONDARY OPERATIONS AND ASSEMBLY: We perform a wide range of secondary operations in-house, including:
  • Application of medical adhesives to molded parts
  • Pad printing of silicones and plastics
  • Ultrasonic welding in a Class 100,000 white-wall environment
  • Die-cutting
  • Assembly
  • Cryogenic Deflashing
Package Design 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 will route trucks to retail stores or distribution centers or process orders and ship to individual customers via U.S. Mail, UPS or FedEx.