Successful custom manufacturing starts with a well-designed solution. Using 3D CAD (Computer-Aided Design), we develop detailed product designs and create prototypes for a wide range of reusable transport packaging and material handling applications, including handheld containers, plastic pallets, bulk containers, and more. In this stage, we can conduct load and stress testing simulations to evaluate structural performance under anticipated operating conditions. This process detects potential stress points, and assesses load-bearing capabilities, which helps our team refine designs to meet the demands of your application. Our design and prototyping processes reduce uncertainty, and allow us to confidently move custom products toward manufacturing.

Capabilities include:
– 3D CAD design and product modeling
– Custom product design and engineering
– Prototype development and evaluation
– Load capacity and stress analysis simulations
– Design optimization for strength, durability, and functionality
– Application-specific design modifications

Custom injection molding delivers consistent, repeatable production of durable plastic products with complex geometries and precise dimensional requirements. Injection molding is well suited for applications requiring strength, uniformity, and long service life.

Injection molded products can incorporate reinforced structures, integrated handles, stacking features, dividers, and other functional design elements. Once the tooling is developed, injection molding provides an efficient, scalable manufacturing solution for medium- to high-volume production runs.

Common injection molding applications: Custom plastic pallets, reusable totes/handhelds, distribution containers, trays, bins, and specialty packaging components.

Custom plastic thermoforming provides a versatile and economical manufacturing solution for producing durable, lightweight plastic products in a wide range of shapes and sizes. This process uses heat to soften thermoplastic sheets, which are then formed over or into precision molds using vacuum or pressure. Thermoforming offers excellent design flexibility, making it ideal for applications requiring custom dimensions, contoured surfaces, and specialized product configurations.

With lower tooling costs compared to injection molding, thermoforming is particularly well suited for low- to medium-volume production, large-format components, and custom packaging applications. Products can incorporate reinforced features, textured surfaces, and specialized geometries to improve product protection, handling efficiency, and durability.

Common thermoforming applications: Custom plastic trays, material handling totes, inserts/dividers, custom dunnage, protective covers, plastic pallets, and specialty industrial containers.

Rotational molding, also known as rotomolding, is an effective manufacturing process for producing large, hollow plastic products with a seamless, one-piece construction. This method provides design flexibility for custom shapes, complex contours, and products requiring enhanced resistance to impact, moisture, and harsh operating environments.

Rotomolding is typically a slower process than injection molding, resulting in longer cycle times during production. Rotomolded products are particularly well suited for lower-volume specialty applications where traditional injection molding may not be economically practical. The process also accommodates thicker walls, molded-in features, and customized configurations.

Common rotomolding applications: Large-capacity bins, industrial containers, sorting and bin store tables, liquid storage tanks, material handling carts, and specialty bulk handling products.

Custom metal fabrication provides strong, versatile solutions for demanding storage, transportation, and material handling applications. Utilizing welded and bolted construction methods, custom metal products can be engineered to meet specific load capacities, dimensional requirements, and operational needs. Welded construction delivers rigid, permanent assemblies designed for structural integrity and long-term durability, while bolted construction offers modular flexibility, simplified assembly, and the ability to modify or replace individual components.

Both styles of custom metal fabrication accommodate tailored configurations, reinforced structures, specialized lifting points, and stacking features. Depending on the application, products can be designed for maximum strength, efficient transportation, or convenient assembly and maintenance.

Common metal fabrication applications: Custom steel storage racks, returnable transport rack systems, industrial carts, material handling frames, modular storage systems, and specialized equipment supports.

Plastic cut and weld fabrication offers a practical solution for producing custom plastic products without the expense of injection molding or rotational molding tooling. Using thermoplastic materials designed for bonding, existing containers and components can be precision-cut, formed, and welded into specialized shapes and configurations.

This plastic cut and weld manufacturing process is especially valuable for prototypes, low-volume production, oversized products, and applications requiring unique dimensions, configurations and weight requirements. Materials such as HDPE and polypropylene can provide excellent moisture resistance, chemical resistance, and durability for industrial environments.

Common plastic cut and weld applications: Custom plastic bins, fabricated containers, industrial tanks, equipment enclosures, dividers, and specialty material handling products.

Custom corrugated plastic fabrication provides a versatile solution for producing reusable packaging and material handling products in a variety of sizes, configurations, and colors. Using fluted polypropylene sheet material, we manufacture custom boxes, containers, dividers, inserts, and protective packaging components designed around your specific application.

Precision cutting, scoring, folding, and joining techniques allow for customized features such as integrated handles, removable dividers, access panels, ventilation holes, and specialized printing. Lightweight, moisture-resistant, and reusable, corrugated plastic products offer an economical alternative to traditional packaging materials while supporting efficient handling, storage, and transportation.

Common applications: Custom corrugated plastic boxes, reusable shipping containers, agricultural packaging, interior dividers, protective dunnage, layer pads, retail displays, and specialty packaging components.