Plastics Pipeline Blog

Setting New Standards:
Team 1 Plastics’ Latest Injection Molding Innovation

What is Innovation?
Innovation is the process of developing new ideas or improving existing ones to create better solutions, products, or services. It involves creativity, problem-solving, and the application of new technologies or methods to meet evolving needs and challenges. At Team 1 Plastics, innovation is at the heart of everything we do. It drives us to continuously improve and deliver superior products to our clients.

 Unmatched Precision and Durability
Our latest innovation, a light pipe for the inside of a taillight system, is engineered with precision and durability at its core. Leveraging advanced plastic injection molding techniques, we have developed a part that not only meets but exceeds industry standards. Our state-of-the-art machinery and rigorous quality control processes ensure that each piece is crafted to perfection, providing our customers with the reliability they need.

A Unique Project
This project stands out as a unique endeavor for Team 1 Plastics. The new part comes from a new customer, involves collaboration with a new toolmaker, and is produced on our newest 450-Ton molding machine. This combination of new elements showcases our ability to adapt and excel in dynamic environments, further solidifying our reputation for precision, quality, and consistency.

Innovative Solutions to Unique Challenges
“Initially, we planned to use a simple gate cutter or cutting fixture to cut the gate,” shared Engineering Manager Dave Seedorf. “This approach proved unfeasible due to the complex contour and detail of the part, as well as its rotation in the tool.” To address this, we implemented a backup plan involving a cobot (collaborative robot) to accurately follow the contour of the part and cut it precisely.

The challenge was significant: the angle required to cut the gate flush was not feasible. During the pre-development stage, there were complaints about cracked parts and gates not being flush. However, since deploying the cobot, we have had no such issues. Additionally, the part’s unique detail, including a tight radius, meant that traditional machining methods wouldn’t work. Many other manufacturers declined to quote on this project due to its complexity. We had to reach out to a new toolmaker, outside our usual network, to meet the specialized requirements. The tool was also expensive due to the special requirements for the machine, testing, and data validation.

Complexity and Collaboration
This large project involved producing a huge part with both left and right-hand versions, which required the use of one of our three larger 450-Ton machines. The complexity of the component required specialized steel optic mold inserts to create the refractor detail, which were made by a special company in Canada. This required extensive testing and validation, involving our outsourced mold maker who further outsourced the insert production.

“Throughout the project, we faced numerous fit and function challenges, including warpage issues and assembly problems on the customer’s side,” explained Dave Seedorf. These required extensive adjustments and tuning to ensure the part worked seamlessly in the customer’s assembly line. 

Hear from Our Team
We spoke with key team members about this new part and the challenges that came along with this unique project. Here’s what they had to say:

• Dave Seedorf, Engineering Manager: “It’s easy at first glance to walk away. To invest the time and research to understand what is feasible and possible, you have to be willing to take risks to make it happen.”
• Mitch Hemgesberg, Project Engineer II: “If we hadn’t had the 450-Ton, we wouldn’t be able to do this job. The larger molding machine has expanded our capabilities.”
• Craig Carrel, President and Co-owner: “This has been one of the larger projects with lots of modifications to make it work and lots of time with the customer/special testing.”

Why Choose Team 1 Plastics?
Precision, quality, and consistency will forever be at the heart of what we do at Team 1 Plastics. Our advanced manufacturing processes guarantee the highest level of precision, ensuring that every part fits perfectly and functions flawlessly. We adhere to stringent quality control measures, ensuring that each part we produce is of the highest quality. Our commitment to consistency means that you can rely on us for parts that perform exactly as expected, every time.

If you want to learn more about how Team 1 Plastics can meet your plastic injection molding needs, please contact us at (517) 629-2178. We look forward to partnering with you.