Capabilities

Small Part Injection Molding

PSI Molded Plastics brings precision and efficiency to small and medium part applications with more than 75 presses ranging from 22 to 450 tons. Whether you need intricate geometries, tight tolerances, or high-volume production, our molding expertise ensures consistent, cost-effective results.

Small Black Parts
Small Red Parts

Why choose PSI for small parts?

  • Ability to produce complex, highly detailed shapes with precision
  • Compatible with a wide range of thermoplastic materials
  • Scalable automation for high production output at lower labor costs
  • Multi-cavity molds enable many parts in a single cycle
  • Consistent repeatability and tight tolerances for quality assurance
  • Minimal finishing required and virtually zero material waste

From medical devices to automotive components, our small-part molding capabilities help clients achieve reliable, high-quality production at competitive cost.

Large Part Injection Molding

PSI Molded Plastics delivers unmatched large-part molding capabilities in the Northeast, with 26 presses ranging from 450 to 1,574 tons—soon expanding to 2,100 tons. Our advanced equipment supports shot sizes up to 31 lbs, giving customers the flexibility to produce larger, more durable components at scale.

Large Red Part
Large White Part

What sets PSI apart?

  • Specialized expertise in injection, structural foam, and gas-assist molding
  • Robotics and custom end-of-arm tooling ensure consistent quality and competitive cycle times
  • Comprehensive finishing services—including painting, decorating, EMI/RFI shielding, and assembly—streamline your supply chain
  • Capacity to handle large, complex parts with efficiency and reliability

From automotive and industrial applications to consumer products, our large-part molding solutions combine scale, precision, and speed to meet demanding production requirements.

Structural Foam Injection Molding

PSI Molded Plastics specializes in structural foam molding, a process that combines a solid exterior skin with a lightweight foam core. By introducing a blowing agent and adjusting process parameters, we create strong, dimensionally stable parts with reduced weight—ideal for large, complex applications where strength and cost efficiency are critical.

Structural Foam 1
Structural Foam 2

Why Structural Foam?

Design advantages:

  • Up to 15% lighter than solid injection parts
  • Lower injection pressure supports larger part sizes and thicker walls (up to 0.500”)
  • Reduced sink marks and tooling costs

Performance benefits:

  • Higher stiffness-to-weight ratio
  • Reduced part stress for improved durability
  • Enhanced thermal, acoustic, and electrical insulation properties

Material Flexibility

Structural foam molding supports a wide range of thermoplastics, including: Polycarbonate, PPO (Noryl), PBT (Valox), ABS, and more.

Design Considerations

  • Allows thick ribs and bosses without warpage
  • Supports brass inserts for threaded applications
  • Produces a solid, durable look and feel with less weight
  • Typically finished with paint for enhanced appearance
  • Slightly slower cycle times compared to standard injection molding

Gas Counter Pressure Option

For premium finishes, PSI offers gas counter pressure molding—pressurizing the mold prior to injection to achieve:

  • Smooth, high-gloss surfaces
  • In-mold textures without painting
  • Extremely flat, dimensionally stable parts
Structural Foam 3

Gas Assist Injection Molding

PSI Molded Plastics offers gas assist injection molding, a process that injects nitrogen into the melt stream to create hollow channels within the part. This results in stronger, lighter, and more efficient components that maintain the appearance and finish of traditional injection molding.

Gas Assist 1
Gas Assist 2

Why Gas Assist?

  • Strength & Rigidity: Tubular structures within the geometry increase durability without added material.
  • Weight Reduction: Thick sections can be hollowed out, significantly reducing part weight.
  • Design Flexibility: Enables larger, thicker sections while minimizing warpage.
  • Superior Surface Finish: Produces smooth, high-quality surfaces comparable to standard injection molding.

Material Versatility

Compatible with most thermoplastics, including: Polycarbonate, PPO (Noryl), PBT (Valox), ABS, HIPS, Polypropylene, and HDPE.

  • Thermoplastics are recyclable and RoHS compliant, ensuring sustainable and globally accepted solutions.
Gas Assist 3
Gas Assist 4

Design Considerations

  • Careful placement of gas entry and exit points is critical for optimal flow and hollowing.
  • Best suited for geometries designed with smooth flow paths and minimal sharp corners.

Secondary Processes

Secondary Processes 1

PSI Molded Plastics goes beyond molding to deliver complete, value-added manufacturing solutions under one roof. Our comprehensive secondary services help streamline supply chains, reduce costs, and ensure products are market-ready.

Assembly & Sub-Assembly

  • Full turnkey capabilities—from individual component sub-assemblies to complete product builds
  • Precision processes that reduce lead time and simplify logistics
Secondary Processes 2
Secondary Processes 3

EMI/RFI Shielding

  • UL-recognized spray-on coatings for effective electromagnetic and radio frequency interference protection
  • Lighter, more efficient alternative to bulky sheet metal liners and enclosures
  • Helps lower part count and overall production costs

Finishing & Post-Molding Services

  • In-house paint facilities, including textured and soft-touch finishes
  • Multiple decorating options: hot stamping, decals, screen printing, pad printing, laser etching
  • Welding solutions: adhesive, heat, solvent, spin, and ultrasonic
  • Additional services: heat staking, custom packaging, bar coding
Secondary Processes 4

By offering secondary processes alongside advanced molding, PSI Molded Plastics saves clients time, resources, and complexity—providing a truly integrated manufacturing experience.