Mold Design Services
Mold design is a Plastek specialty. Our in-house team implements the most advanced concepts and practices when creating custom products for your company’s needs. We tap into our diverse backgrounds and unparalleled expertise when creating molds that meet your specifications. We also utilize advanced software solutions to guide us through the process and enable us to make informed decisions:
- Mold Flow/Mold Cool
- AutoCAD Mechanical Desktop
- Simulia Abaqus
- Pro Engineer (3D Mold & Product Design)
- Expertise Mold Designers
We’ve created a comprehensive document database to coordinate, organize, and secure all relevant engineering data and make it easily accessible to our engineering staff.
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Our Engineering Team
Our experienced and knowledgeable cross-functional group of engineers cover multiple disciplines to ensure we provide the most comprehensive results. We implement a collaborative approach when partnering with our customers to develop innovative concepts that ensure a robust, reliable, and efficient supply chain.
Our engineers will bring these concepts to life by creating fully functional prototypes and production tooling processes. You can have confidence that the product we ultimately develop will provide the right solution for your business.
Fully Equipped Tool Shops
With four strategically located facilities, Plastek can execute high-quality contract plastic manufacturing projects for companies around the globe. Our fully equipped tool shops employ a large staff of toolmakers, engineers, and project managers, who share an unwavering commitment to delivering the best outcomes for every customer.
Our experience and expertise have enabled us to establish industry standards for designing and constructing molds in press maintenance and component interchangeability applications. We’ve also instituted toolmaking apprenticeships and other training initiatives to ensure our workers perform at a high level.
Examples of the advanced solutions we utilize in our tool shops include innovative CAD/CAM technologies that deliver superior results when designing parts and manufacturing molds. These systems also provide immediate updates to ensure we have the most accurate customer information on file.
Choose Plastek for Your Mold Design and Manufacturing Needs
With locations in the United States, the United Kingdom, Brazil, and Mexico, we have grown to become a world class leader in plastic and mold manufacturing for the Personal Care, Beauty, Home Care, Pharmaceutical, and Food and Beverage Packaging Industries. We specialize in Industrial Design, Product and Package Development, Injection, Injection Blow Molding, Custom Plastic Fabrication, and Injection Stretch Blow Molding as well as value added Assembly and Decorating.
Frequently Asked Questions (FAQs)
At The Plastek Group, our mold design and manufacturing process is fully integrated and highly collaborative. We begin with upfront design-for-manufacturability (DFM) and engineering reviews to optimize part quality, cycle time, and tooling longevity. Our in-house engineering teams leverage advanced CAD, simulation, and validation tools to ensure robust designs before steel is cut.
Tooling is then manufactured through a combination of our global tool-build partners and internal oversight, followed by comprehensive tryouts, qualification, and ongoing maintenance support to ensure consistent, high-volume production performance.
The Plastek Group supports a wide range of industries that demand high-precision, high-volume injection molding solutions. These include personal care and beauty, home care, food and beverage packaging, pharmaceutical and healthcare products, battery and energy storage components, industrial and consumer products, and select automotive and aerospace applications.
Our experience across regulated and high-performance markets allows us to tailor tooling solutions that meet strict quality, durability, and scalability requirements.
Yes. The Plastek Group specializes in large-scale and complex mold manufacturing programs. We routinely manage multi-cavity and multi-tool projects designed for high-volume global production. Our teams provide end-to-end project management, from initial design and sourcing strategy through validation, launch, and long-term support.
This approach enables us to deliver scalable, cost-effective tooling solutions while maintaining tight quality and timeline controls for enterprise-level customers.
The Plastek Group offers comprehensive mold design and high-volume injection molding production as one of our many integrated capabilities. Our in-house engineering teams create custom molds, then manufacture them in our fully equipped tool shops spanning the U.S., UK, Brazil, and Mexico. We serve high-volume markets including personal care products, health and beauty, home care, pharmaceutical and nutraceutical products, and food and beverage.
The Plastek Group offers fully integrated mold manufacturing, handling both tooling and high-volume production in-house. This comprehensive approach ensures seamless project management from initial design to ongoing maintenance, which optimizes part quality and cycle times. Our expertise guarantees precise, cost-effective, and scalable solutions for even the most complex projects.
The Plastek Group specializes in a wide range of plastic polymers for injection molding. While we focus on high-density polyethylene (HDPE) and polypropylene (PP), we also work with custom resins tailored for industrial, consumer goods, and packaging applications.
Yes, the Plastek Group provides prototyping for rapid tooling services. Our integrated design-for-manufacturability (DFM) and engineering assessments inherently support efficient prototyping and rapid validation. Our in-house engineering teams leverage advanced CAD and simulation tools to quickly refine designs and ensure optimal manufacturability. This approach allows us to streamline the development cycle and prepare robust tooling solutions with speed and precision.
The Plastek Group adheres to various quality certifications and standards, such as the following, to ensure regulatory compliance:
- ISO 9001: We meet ISO 9001 standards to uphold our commitment to quality management.
- ISO 13485: We adhere to ISO 13485 in our designs and processes for medical devices.
- FSSC 22000: We ensure FSSC 22000 compliance for packaging that involves food contact applications.
The Plastek Group’s manufacturing facilities are located across North America, South America, and Europe. Our global reach enables us to supply custom molds and plastic packaging to major international industries and markets.
The Plastek Group offers the following pre-manufacturing capabilities to support product development and ensure products are optimized for functional performance, shelf appearance, and efficient production:
- Industrial design
- Research and development
- Rapid prototyping
- Mold design and analysis
- Custom tool and mold making
- Metrology and testing
- Guidance on regulatory compliance
Minimum order quantities vary based on part complexity, material selection, and tooling requirements. The Plastek Group specializes in large-scale production runs and works closely with customers to define feasible order quantities tailored to your business goals. We consider requests to perform injection molding using a variety of plastic resin materials.
While our most popular solutions include Polypropylene and High-Density Polyethylene, we can quote for and manufacture products in resins such as Post-Consumer Resin and Low-Density Polyethylene. Contact our sales team, or your senior account manager to discuss your specific volume requirements.
We maintain consistent part quality through rigorous process controls and real-time monitoring protocols. Our adherence to industry standards, including BRCGS Packaging Materials Issue 6 and ISO 9001 certifications, combined with advanced CAD/CAM technologies, ensures molded components meet required specifications. We validate multi-cavity mold designs using simulation software before production begins, minimizing variability and promoting repeatability at scale.
Yes. Our global manufacturing network provides flexible capacity designed to accommodate seasonal surges and unexpected demand spikes. We balance workload across sites while working to maintain delivery schedules and consistent quality standards. Your assigned project manager monitors production timelines proactively, providing the communication and visibility you need during critical growth periods.