Thermoset Injection Molding Services

MCM Composites, LLC specializes in manufacturing thermoset injection molded parts, especially suited for the electronics and appliance industries. Through precision injection molding, we produce intricate as well as large parts made from phenolics, alkyds, polyester (both BMC and SMC), carbon fiber compounds, and composite material. The weight of these parts ranges from 0.1 grams to 10 pounds. Our custom mold shop is equipped with a range of electrical and hydraulic injection molding presses with tonnage capacities ranging from 75 tons to 500 tons. These molding presses are equipped with degas sequence, gate cut sequence, core pull, and runnerless injection compression systems.

MCM’s manufacturing plant also houses a quality lab, tool repair shop, plus cool room for storing perishable raw materials and customers’ molds. Our fully equipped tool shop enables us to design unique tools to create molds as well as offer repair and maintenance services for customers’ molds. We work in conjunction with our customers, toolmakers, and tool designers to construct initial 3D models of the products. In-house tooling capabilities assist us to optimize product quality, maximize production efficiency, and minimize product cost. Molded parts, manufactured from our specially formulated high-strength, thermoset composites, can be used as economical alternatives to stamped or formed parts, aluminum extrusions, and other machined components.

Through thermoset injection molding, we also fabricate parts that offer superior mechanical performance at temperatures as high as 260°C and multi-piece part assemblies into a single mold. Secondary services such as tapping, drilling, and coating, as well as multi-piece assembling are also offered on injection molded parts.

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Injection Molding Capabilities

ISO Certification: ISO 9001:2015 Registered

Tolerances the machines can produce repeatedly: +/- .0015

Material List: Alkyds
Carbon Fiber Compounds
Melamine-Phenolics
Phenolics

Polyester (Both BMC and SMC)
Melamine
Epoxies
Vinyl Ester (Both BMC & SMC)

Applications: Arc Shield
Contactor
Cup Coffee Pot Base
Electrical Components
Fan Components
Cookware Handles

Hair Clipper Housings
Headlamp Housing
Impellers
Motor Shrouds
Terminal Blocks

Injection Molding Specialties: Insert Molding

Part Weight: 0.1 grams to 10 lbs

Production Runs: 1 Piece to over 1,000,000 Parts Annually

Tonnage Capacity: 75 tons to 500 tons

Platen Size Range: 18.7″ x 20.7″ to 46.1″ x 46.1″

Colors: Custom Colors

Secondary Services: Deflashing
Drilling
Epoxy
Gluing
Machining
Metal Insertion

Metallizing
Painting
Post bake
Potting
Tapping

Value-added Services: Engineering Assistance for Metal-to-Plastic Conversions
Feet, Clip, and Decal Installation
Multiple Piece Assembly
Testing of Prototype Tools

Tooling Design & Maintenance

Tooling engineering staff with experience in all mold types with many design characteristics, such as rising islands, gate cutoff, and cold manifold.
Design each tool to create a mold to optimize product quality, maximize production efficiencies, and minimize product cost.
Fully equipped tool shop to repair and maintain all of our customers’ molds.
Regular maintenance of molds. Each mold reviewed after each production run.

Thermoset Injection Molding Advantages

Dimensional stability
Mechanical strength
Cost advantage versus machined aluminum or steel parts
Cost advantage versus assembled aluminum or steel parts as multiple pieces can be molded as one
Creep resistance
Electric insulating qualities
Thermal insulating qualities
Sound dampening
Low expansion coefficient
Low flammability
Low fluid absorption (water or chemicals)
No corrosion

Quality Certifications: ISO 9001:2015 Registered

Software Used: AutoCAD
Fusion 360
SolidWorks

MasterCAM
SpinFire

Acceptable File Formats: DWG
DXF
GIF

PDF
STEP

Industries Served: Appliance
Aerospace
Batteries
Defense
Electrical
Food & Beverage
Fracking & Oil Field

Housewares
Lighting
Medical
Outdoor Grills
Park & Recreation
Pumps
Restaurant