State-of-the-Art Production Capabilities

High-Performance Polymer Manufacturing Done Right

As a high-performance polymer manufacturer and injection molder, we can consistently solve difficult design problems and deliver precision parts on time with rejection rates well below industry standards.

Whether you need one or a million high-performance plastic components, our team will work with you to meet your specs—as well as your standards, timelines, and budgets. We relentlessly solve problems, continuously improve processes, and tailor our skills and capabilities to meet the needs of our customers. That’s why we’re the go-to high-performance polymer component manufacturer and injection molder for companies in many industries.

We also approach each project with proven engineering expertise, industry-leading process management, state-of-the-art equipment, and incomparable customer service. We use scientific molding, decoupled processes, and closed-loop controls and have RJG-certified Master Molders on staff—all of which ensure you get parts that are consistently high-quality and on time.

With molding capacities ranging from 20 tons to 500 tons, tie bar spacing from 10” to 10” (smallest) and 32” to 33” (largest), and shot sizes from .39 ounces to 60 ounces, Allegheny Performance Plastics is well-equipped for prototypes or production runs of any size.

Many injection molders rely on people for quality control, which requires inspectors to constantly check parts and tweak a molding machine’s control settings. Our processes include the use of RJG sensors, which allows the machine to make processing adjustments within a certain range. This reduces costs because one person can monitor several injection molding machines at once. The RJG eDART® process control system is the most powerful process control system for plastic injection molding applications. Additionally, we operate customer-focused work cells—which makes us just as attentive to people as part production.

In-House High-Performance Polymer Capabilities

High-Performance Polymer Molding

• Injection molding
• Overmolding
• Insert molding
• Mold building

Polymer Machined Parts
We understand the unique characteristics of high-performance polymers and have the expertise to machine complex geometries on our CNC lathes and 3D mill. We also have the staff to assist with the client design process.

We use the most up-to-date techniques to ensure quick and accurate prototypes or manufacture complex production runs. This is key because it makes a part cost-effective and it is also critical in providing a quality part.

CNC Machining Lathes & Milling Centers

• Prototypes
• Part production
• Metal component production
• Mold building

Our facility has specialized CNC machines and equipment that allows us to build molds for any industry. One of the tools used in making injection molds is electrical discharge machining (EDM). The EDM machine helps us create complex shapes and difficult tool designs.

We also understand that time is everything in product development, so to help speed up time to part production we groom (modify) tools made from other manufacturers. This helps shorten lead times and lower shipping costs. We also conduct routine maintenance and repairs on all production tools in-house, which lessens the interruption to our manufacturing operations as well as our customers.

Thermal Processes

• Annealing
• Curing

We have 40 ovens in-house that can be used for any plastics that require post-processing annealing or curing. We currently use the ovens to develop crystallinity in some polymers, or, in the case of Torlon®, one of the highest performance materials we work with, the ovens allow for plastic crosslinking that significantly boosts material performance and capability. The curing and annealing cycles take anywhere from hours to weeks depending on the material.

We have high-performance polymer technology that no competitors have, in both processing, injection molding, machining and in the post-cure process. We leverage this technology to be able to bring Torlon® parts to the market at a more affordable price.

Secondary Processes

• Bonding
• Ultrasonic welding
• Balancing
• Testing and analysis
• Specialty and custom processes

Assembly

• Component assembly
• Assembly testing

Transfer Tooling Program
Do you have a molder that has been unsuccessful in molding high-temperature, high-performance polymers? Some of our most successful programs began as a tool transfer program. We can take existing tooling, facilitate the transfer to our facility, inspect, make repairs, and perform complete verification testing. For every transfer, we strive to minimize downtime and exceed quality expectations. We understand that every tooling transfer situation is unique, and we are able to meet your demands.

Essential elements for success:

• Initial/Budgetary quotation: Typically made with numerous assumptions because of missing information. Only used to validate economics.
• Pre-transfer planning: Gather as much information about the tooling, tooling history, program history, and historical quality issues. Our team is willing to do an on-site evaluation (if possible) while the tooling is running and/or being maintained, conducting an evaluation of part quality, and understanding the application requirements by reviewing the assembly.
• Final proposal: Including final pricing, scenarios for tool work, project timing, buffer inventory requirements, and clarifying requirements for future tool maintenance.
• Execution.

A High-Performance Polymer Component Manufacturer You Can Trust

At Allegheny Performance Plastics, we use the right mix of people, equipment, and services to meet the unique needs of each project. Our rapid in-house prototyping and relentless problem-solving have made us a trusted partner to Fortune 500 original equipment manufacturers (OEMs) and Tier 1 suppliers.