Eliminating Secondary Operations with Molded-In Features
Secondary operations – machining, fastening, welding, and finishing – can quickly drive up production costs and extend lead times. Every extra step in manufacturing adds labor, increases material waste, and introduces potential quality issues. Molded-in features eliminate these unnecessary operations by integrating critical design elements directly into the part during the molding process.
For manufacturers looking to reduce costs, improve efficiency, and enhance part durability, structural foam molding with molded-in features provides a streamlined solution. DeKALB Molded Plastics helps customers simplify production and maximize cost savings with design strategies that eliminate the need for post-molding modifications.
Read on to discover how molded-in features can transform your production process.
The High Cost of Secondary Operations
Many manufacturers accept secondary operations as part of the production process without realizing how much they add to overall expenses. Drilling, tapping, assembling, and surface finishing all require additional labor and equipment. These extra steps also introduce variation, increasing the potential for defects, misalignment, or part inconsistencies.
Molded-in features remove these costly and time-consuming processes by incorporating essential design elements from the start. Integrating mounting points, ribbing, fastener-free connections, and textured surfaces into the mold reduces part handling and post-molding work. Fewer steps mean a faster, more efficient path from production to final assembly.
Beyond cost savings, eliminating secondary operations improves part performance. Every drilled hole, welded joint, or bolted connection creates potential failure points. A molded-in approach strengthens the overall structure, reducing the risk of weak spots and ensuring long-term durability.
How Molded-In Features Drive Cost Savings
Manufacturers can get more out of each product without extra processing thanks to molded-in features that improve function and manufacturability. Common examples include:
- Threads & Inserts Molded-in threads eliminate tapping and secondary machining. Brass inserts can be integrated during molding for added strength.
- Reinforcement Ribs Additional strength without increasing material thickness, reducing both weight and cost.
- Mounting & Fastening Points Molded-in attachment points remove the need for separate brackets or hardware.
- Textured Surfaces & Branding Logos, serial numbers, and surface finishes can be part of the mold, reducing post-processing requirements.
Each of these molded-in solutions eliminates labor-intensive steps, reducing cycle times and making production more cost-effective. Fewer operations mean fewer opportunities for errors, rework, or rejected parts, further improving efficiency.
Industry Applications: Where Molded-In Features Make a Difference
DeKALB Molded Plastics serves industries that demand durable, high-performance plastic components with built-in functionality. Molded-in features enhance medical enclosures, safety equipment, and material handling solutions, eliminating extra processing while improving efficiency and part longevity.
Medical Housings, Structures, & Cabinetry
Molded-in mounting points simplify assembly while eliminating external brackets and fasteners, reducing assembly time and material costs. Seamless, easy-to-clean surfaces meet hygiene requirements, and molded-in cable routing helps organize and protect wiring.
Safety Enclosures & Devices
Reinforcement ribs molded into enclosures increase strength without added weight, improving impact resistance and product longevity. Integrated handles, mounting features, and textured surfaces enhance functionality while reducing production complexity.
Specialty Material Handling
Plastic pallets, bins, and transport containers perform better when structural reinforcements and functional features are molded in. Fork pockets, tie-down points, and slip-resistant textures are integrated directly, reducing the need for post-molding modifications.
DeKALB’s Approach: Smarter Design for a More Efficient Process
DeKALB Molded Plastics helps customers eliminate unnecessary steps by optimizing part designs for molded-in features. The ability to mold large, complex parts with multiple integrated functions reduces material handling, streamlines production, and lowers costs without sacrificing performance.
Beyond molding, in-house painting, labeling, and packaging keep production efficient and reduce the need for third-party services. Engineering expertise ensures that every part is designed for maximum functionality with minimal post-processing.
Takeaways
Manufacturers looking to reduce costs and streamline production should rethink secondary operations. Molded-in features remove unnecessary steps, lower labor costs, and improve part quality, delivering faster, more cost-effective solutions.
DeKALB helps customers design parts that work smarter, not harder – eliminating extra processing and maximizing efficiency. Interested in cutting production costs with molded-in features? Let’s discuss how we can help – contact us today!