Post-mold Assembly & Value-added Operations
Post-Mold Assembly & Value-Added Operations
At ExportPlastics, our services extend far beyond injection molding. We provide integrated post-mold assembly and value-added manufacturing solutions that ensure your components are delivered fully assembled, performance-tested, and ready for end-use or integration. These services are aligned with ISO 9001:2015 quality management standards, designed to optimize manufacturing efficiency, reduce cost, and ensure product compliance from start to finish.
Comprehensive Post-Mold Assembly Capabilities
With both manual and automated assembly systems in place, we can handle diverse production volumes and complexity. Our assembly operations follow documented work instructions, are traceable, and are performed in a controlled environment to minimize defects and reduce rework.
- Snap-fit, press-fit, and friction-fit assembly
- Custom kitting and packaging preparation
- Installation of grommets, u-clips, springs, push nuts, and foam liners
- Assembly of electrical wire harnesses and connectors
- Manual and robotic application of weatherstrips and seals
- Barcode and 2D code application for traceability and inventory integration
Plastic Welding Capabilities
Our plastic joining solutions include both sonic welding and heat-staking — engineered to deliver robust, consistent bonds while meeting strict dimensional tolerances. These processes are ideal for multi-part plastic assemblies and are executed under controlled temperature and vibration parameters, validated per project-specific control plans.
- Sonic Welding: Ultrasonic vibrations create frictional heat that bonds parts at the molecular level. Best for small to medium-sized components with tight tolerances.
- Heat-Stake Welding: Uses localized heating and forming pressure to reshape plastic around another part for a permanent mechanical bond. Suitable for large or structural assemblies.
Integrated Error-Proofing Systems (Poka-Yoke)
We apply robust error-proofing practices during assembly to prevent incorrect part orientation, incomplete connections, or missed process steps. These systems include sensors, precision tooling, visual indicators, and in-process validations. Our goal is zero-defect output at the source — not downstream.
- Automated sensor checkpoints with feedback loops
- Tooling with mechanical interlocks to prevent incorrect alignment
- Vision-guided inspection systems for orientation and fit
- Built-in fail-safes that stop production if quality thresholds are not met
Tooling Maintenance & On-Site Repairs
To minimize downtime and maintain continuity of supply, ExportPlastics performs on-site mold and tooling repairs. Our internal team can troubleshoot, service, and restore molds to operational status without third-party delays, keeping your production running to schedule.
- Preventive and corrective maintenance programs
- Tool inspection logs and lifecycle tracking
- Quick-repair station for non-critical tool adjustments
Dimensional Inspection & Quality Control
Our in-house Coordinate Measuring Machine (CMM) allows us to verify dimensional and geometric tolerances before and after assembly. Each part undergoes inspection based on control plans and sampling rates aligned with ISO 9001 and customer-specific requirements. Test results are recorded and retained to ensure product traceability and compliance.
- CMM-based dimensional verification
- Gauge and fixture inspections for key part features
- Documentation of First Article Inspection (FAI) and PPAP as required
- Final audit inspections with part validation before shipping
At every stage of post-mold operations, ExportPlastics integrates precision, accountability, and ISO best practices to deliver parts that perform — right out of the box. From tooling to testing, we are your full-cycle plastic manufacturing partner.