Package Design & Development

This video displays industrial design added value service examples from Plastek’s Innovation Corner.
The Plastek Group

Research & Development

At The Plastek Group, innovation is a pillar of our operating philosophy. Our research and development engineers are constantly innovating new products through a comprehensive multi-step creative process. Continuously adding new designs to our internal library of developed product design options, enables us to expand our customer offerings.  We provide consistent critical expertise during every phase of a product development project. Our extensive collection features the most advanced designs prepared to exceed our customers’ expectations, and retain our position as an industry leader and innovator.

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Above is an example of a product that passes through the product development stage.
The Plastek Group

Injection Molded Package Development

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If you need to create plastic packaging for pharmaceuticals, health and beauty products, automotive components, or other product lines, consider working with The Plastek Group.

We’re dedicated to providing our customers with the highest-quality plastic components while maintaining our commitment to sustainability, wellness, and safety.

Contact us today for more information about custom plastic injection mold designs from The Plastek Group.

Play Video: Plastek’s R&D personnel are committed to provide consistent critical expertise to all aspects of each customer’s development project.
The Plastek Group

The Plastek Team

Whether we’re developing custom plastic injection mold designs or engaging in other aspects of the packaging development process, we implement a team concept to deliver the best outcomes for our customers. We bring vast expertise in several critical areas. Project management and engineering, injection molding prototyping, product cost studies, industrial design, and high-level communication skills are all key aspects of the repertoire.

Communication is the common element that bolsters our team concept. It allows these diverse personnel groups to collaborate during every project phase while keeping the customer’s objectives at the forefront. We also keep the communication lines open for our customers — we welcome and encourage your input.

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The Plastek Group

Packaging Development Process

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Research – Information Gathering

 We review existing and new designs to determine cost savings, sustainability, manufacturability, and appearance. If we’re developing new technologies for a project, we focus on improving functionality or reducing costs in accordance with project objectives.

Development –

Next, our package development team reviews the design to sustainably create a manufacturable concept that is as cost-effective as possible. Using CAD software, we establish the design’s form, fit, and function. We lightweight the design as much as possible while maintaining its integrity, and we select a recyclable material for the final product.

Part Design
Review (PDR) –

Before release, we complete PDR with the Project Manager and the Tooling, Processing, Assembly, and Quality teams. We review critical areas and customer-driven design elements for manufacturability. During this step, Tooling may suggest modifications based on the tool’s complexity and longevity. The customer then reviews all proposed changes for sign-off before we implement them in the final design.

Prototyping –

After defining the product concept, we test the 3D models created during the concept phase using rapid prototype samples, such as SLA, SLS, or FDM. By ensuring all parts function as intended, we limit steel changes, which reduces lead time during tooling.

Presentation –

We create final working models for functional testing to verify the assumptions and decisions made in the previous steps. Using our technological resources, we supply rendering and animation showing shelf impression, assembly sequence, and customer use for final review.

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Current Technology Capabilities

At Plastek, we utilize a variety of technologies to achieve project goals, including the following:

PTC Creo 8.0

We have been using Creo (ProE) for decades. The tool’s moldsplit and ProManufacturing functions provide connectivity from industrial design to tool manufacturing, enabling us to design multi-component packages for FFF.

PDMLink maintains our large database of product and tool designs to ensure proper file storage, allowing for easy file retrieval and transfer between Plastek engineers. This system also keeps the data organized so we can easily reference iterations as needed.

This tool also enables us to:

  • Optimize designs based on predefined parameters.
  • Streamline the additive manufacturing process.
  • Simulate and proactively resolve fluid flow issues before manufacturing.

We use this CAD software from project inception to completion, which allows us to increase efficiencies and shorten response times.

Luxion Keyshot 11

Luxion Keyshot 11 is a rendering and animation software that creates photo-realistic images to:

  • Convey shelf appearance.
  • Animate product assembly and functional use.
  • Convey more detailed product information.

Autodesk Moldflow 2023

Since 2010, we’ve used Autodesk Moldflow on a job-to-job basis as a mold filling analysis tool. This analysis provides information on gate locations, optimal process, cooling, and warpage.

Because most designs don’t have a constant wall thickness, Moldflow helps us catch problem areas created by the design before we move on with the process. Moldflows are done on the original PD design, and fill and pack analyses ensure the lightweight part is still fillable.

Once we complete the initial mold design, we run FEM Moldflow to verify the waterline design. If we find hot spots in the mold, we review them and make the necessary improvements.

We also analyze the part warpage based on cooling variation in the mold. Using this information, we can adjust the design intent model to compensate for the warpage defects before we begin cutting steel.


At Plastek, we use Stratasys 3D printing solutions to build prototype molds for quick turnaround and print products with labels to show on market components. We’re currently capable of:

  • Printing three different colors.
  • Printing market similar designs through our supplier.
  • Printing over-molded, soft touch, and multi-color components.

Our Stratasys printer helps speed up this process, allowing us to produce samples in-house in just a few hours. Compare that to traditional prototyping processes, which can take several days.


How Our Client Relationship Works

We work closely with our clients through every step of the packaging development process:

  1. Ideation: After conducting thorough research and learning about your goals, our designers and engineers begin brainstorming and refining product ideas.
  2. Industrial Design: Our industrial design team uses critical resources like market research to generate a variety of possible product solutions.
  3. Sketching: Our team sketches out each solution to expand the possible packaging options.
  4. Visualization: We use visualization tools like Luxion Keyshot 11 to help our clients see and understand the possibilities for their products.
  5. Results: At the end of the process, our clients see the results of our attention to detail, our striving for innovation, and our dedication to quality.

Choose Plastek for All Your Plastic Manufacturing Needs

If you need to create plastic packaging for pharmaceuticals, health and beauty products, or automotive components, consider working with The Plastek Group. We’re dedicated to providing our customers with the highest-quality plastic components while maintaining our commitment to sustainability, wellness, and safety. Contact us today for more information about custom plastic injection mold designs from The Plastek Group.