From Concept to Completion: DeKALB’s Turn-Key Plastic Molding Solutions
Launching a new plastic component should feel organized, predictable, and efficient. That’s exactly how DeKALB Molded Plastics approaches every project. Customers gain a partner that manages the entire journey, from early design through molding, finishing, assembly, packaging, and delivery, so nothing slips through the cracks.
Read on to see how DeKALB’s turn-key approach keeps programs moving from concept to completion.
Design Support That Starts with the Concept
Every successful molding program starts with a well-designed part. DeKALB’s engineers work side-by-side with customers early on providing design support to review geometry, materials, and performance goals. Those conversations help identify risk areas, strengthen part function, and set realistic expectations before tooling begins.
Design-for-manufacturability reviews take a close look at rib placement, wall transitions, knit lines, and gating to support better flow and cooling. Advanced tools like CAD, FEA, and mold flow simulations guide those decisions, helping balance strength, appearance, and production efficiency.
Material selection is just as critical. DeKALB molds nearly any thermoplastic – from HDPE and PP to ABS, PC, PS, and PPO along with glass- and carbon-reinforced blends for added strength or rigidity. Collaborating early in development helps reduce redesigns, shorten launch timelines, and protect overall program cost.
Structural Foam and Gas Assist, Chosen for the Application
DeKALB specializes in two complementary molding processes: structural foam and gas assist. Both are designed for large, rigid parts that need excellent strength-to-weight performance.
Structural foam combines a base resin with a foaming agent to create a solid outer skin and a lightweight cellular core. The low-pressure process supports thicker wall sections and reduces molded-in stress, delivering strong, stable parts without adding unnecessary weight. Aluminum tooling and lower clamp tonnage can also lower upfront costs for large-scale programs.
Gas assist molding takes the process a step further by using nitrogen to form hollow channels inside thicker sections. Those channels increase stiffness, reduce warp, and create a clean surface with fewer sink marks. The method works well for parts with mixed wall thicknesses, like handles, frames, and machine covers.
With presses ranging from 300 to 750 tons, we tailor each project to the right process to balance performance with cost efficiency and repeatable quality.
Value-Added Services Under One Roof
DeKALB’s capabilities extend well beyond the press. In-house finishing, assembly, and logistics support make it possible to ship production-ready parts directly to customers, saving time, reducing handoffs, and improving quality control.
Capabilities include:
- Fabrication: trimming, drilling, routing, bonding, inserting, and welding
- Painting & Decorating: solvent and waterborne systems, textures, two-tone finishes, splatter coats, masking, and EMI/RFI shielding
- Assembly & Kitting: sonic and induction welding, enclosure builds, mechanical fastening, specialty packaging, and consumer-ready packs
- Inventory Management: sourcing, labeling, and coordinated delivery for smoother supply chain performance
Housing these operations in one facility shortens lead times and keeps every detail under a single point of accountability.
Quality That Drives Every Stage
Quality is built into the process, not inspected at the end. DeKALB follows ISO 9001:2015 standards and uses tools like SPC, Gage R&R, dimensional layouts, and documented setup controls to maintain consistency.
Team-based problem solving, process monitoring, and continuous improvement initiatives help reduce variation and maintain stability from one production run to the next. The result is dependable quality at every stage.
Materials and Design Flexibility
No two applications are the same. Some demand chemical resistance or outdoor durability, while others require stiffness, impact strength, or heat performance. DeKALB’s experience across commodity and engineering thermoplastics makes it easy to match material properties to the job.
Structural foam molding also opens the door to creative engineering solutions. Thick wall sections, molded-in louvers and threads, and multi-part consolidation can all be achieved in one shot. Replacing multiple metal or fiberglass pieces with a single molded component often cuts both cost and assembly time while improving long-term reliability.
Proven in Demanding Markets
DeKALB’s turn-key approach delivers results across a wide range of industries.
- Safety Enclosures & Devices: highway and construction products designed for strength, stability, and impact resistance
- Medical Housings, Structures, & Cabinetry: durable, ergonomic enclosures built to meet tight dimensional and cosmetic requirements
- Specialty Material Handling: rigid bulk boxes and containers engineered for strength, durability, and ease of handling
- Additional Markets: industrial equipment, commercial housings, and custom structural parts that require precision and reliability
Customers in each of these markets trust DeKALB for consistent performance, clear communication, and practical problem-solving. Many programs also incorporate recycled resin to reduce cost and waste without compromising quality or strength.
A Clear Path from Idea to Shipment
DeKALB’s process is designed to keep programs moving. Concept reviews transition smoothly into tool builds, followed by molding trials and full production. Painting, assembly, and packaging are coordinated ahead of time so every part leaves the facility ready for use.
Shipping schedules and inventory systems align with customer demand to keep production lines running. From kickoff to delivery, DeKALB manages each phase with the same focus on communication, efficiency, and accountability.
When the goal is a smoother, simpler path from idea to finished product, DeKALB makes it happen, start to finish.
Contact DeKALB Molded Plastics to learn how a true turn-key partnership can bring your next project from concept to completion.