Plastics

Your trusted partner for advanced plastics

We recognize that advanced plastics play a key role in the future of product development. From consumer products to critical healthcare devices, plastics can set your product apart. Flex supports our customers through product design, tooling, assembly, packaging, and logistics, delivering reliable production outcomes through consistent quality control processes at every production stage.

Our expertise in complex injection molding and mold fabrication for consumer goods and plastic packaging solutions enables us to deliver myriad capabilities: developmental tooling for high-tolerance and rapid pre-production tooling, ultra-high-precision, high-cavitation tooling, high-volume plastic injection molding, automation, assembly, and more.

Developmental tooling

Developmental tooling is critical to ensuring your components and products are highly manufacturable. Our dedicated engineering team partners with you every step of the way, starting with a working template for high-cavitation production molds.

Through a combination of evaluating your products prior to investing in production molds and taking advantage of short-run production opportunities, you can get to market faster with a proven design.

Plastics custom mold manufacturing

Our expertise in plastics custom mold manufacturing speeds production, cuts downtime, and streamlines the production of complex plastic components through our interchangeable core and cavity components.

Measure and correct dimensional issues during manufacturing of electrode making, grinding, and milling with our Self-Correcting Manufacturing (SCM) technology.

Our Advanced Process Validation allows you to establish optimum processing parameters and validation criteria for FDA and other regulated specifications.

Expert plastic injection molding

Flex specializes in expert plastic injection molding, allowing us to provide complex plastic components in high volume at a low cost. Whether you require intricate multi-material parts or streamlined consumer packaging solutions, our advanced capabilities and expertise are ready to support your project needs.

We uphold rigorous quality control and testing procedures to guarantee that every mold meets the highest standards and use simulation software for the part and old design to optimize and prevent problems before the mold is build. We also use Finite Element Analysis (FEA) for products and assemblies to assess structural, acoustic, electromagnetic, and thermal performance.

We can accommodate a variety of project requirements to meet your specific injection molding needs:

• Mold clamping pressure from 25 tons to 1,700 tons
• Multi-material molding (2-, 3-, and 4-shot capability), over-molding, insert molding, and consumer packaging molding
• In-mold value-added operations (in-mold labeling, assembly, and closing)

Tooling design and fabrication

We leverage our extensive experience and cutting-edge technology to deliver customized tooling design and fabrication solutions that meet the highest standards of quality, efficiency, and cost-effectiveness. Whether you require complex multi-material molds or high-volume production capabilities, we’ll make sure your components and products are highly manufacturable so you go to market with only proven designs.

We offer different types of custom molds depending on your product needs.

• Single-face, stack and multi-cavity, multi-material/two shot (multi-component, multi-shot, and over-molding), in-mold automation, insert and unscrewing (single-face and stack) molds
  • In-mold operations (assembly, closing, coining, and labeling)
  • Design and fabrication up to 500 tons

• Complex, high-tolerance molds from prototype through production
• Multi-mold programs, precision high cavitation and close tolerance tooling and injection molds, spin stack molds, rapid pre-production molds, turnkey solutions, and multi-mold programs for high volume

Sustainable delivery

Procure materials faster, build products more cost-effectively, and ship directly to customers with the breadth and scale of our global supply chain network.

You can lower your Total Cost of Ownership (TCO) while improving customer satisfaction through faster, more reliable product delivery.

And along the way, your efforts support a sustainable future thanks to our partnerships with top certified suppliers using environmentally friendly practices.

Precision injection molding and mold fabrication for plastic components in healthcare

As the leading medical device manufacturer for volume production, we have helped top multinational medical and pharmaceutical companies go to market.

Our experience producing plastics for the healthcare market includes medical device components, laboratory consumables, medical disposables, pharmaceutical packaging, and delivery devices. Our expertise means you can produce and deliver the highest level of quality and compliance to your customers, every time.

Precision injection molding

Make our ultra-high-precision injection molding expertise yours. You can depend on our experience manufacturing plastics in healthcare devices, such as drug delivery devices, patches, inhalers, auto-injectors, syringe barrels and plunger rods, plastic implantable devices, and laboratory consumables.

ISO 8 clean room molding

As the leading medical device manufacturer for volume production, we produce highly specialized plastic components and medical devices with the quality and regulatory readiness you need. We have facilities dedicated to the production of medical devices that are ISO 13485:2016 certified, FDA 21 CFR Part 820 compliant, and equipped with ISO Class 7 and 8 clean rooms.

Automated assembly

Set a new pace for operations with less effort. High-speed clean room assembly and packaging, in-house automation design and engineering, vertically integrated manufacturing of the molding process, and high-speed tool room automation all create efficiencies not possible with manual assembly.

Short-run production services also enable requirements for automation, assembly, and preliminary production needs including clinical trial volumes.

Your end result? Cost-effective, high-volume production of finished goods. And more importantly, you can minimize — or even eliminate — the potential for introducing human contaminants into your medical-grade products.

FDA registration and ISO 13485 certification

Our single-source, standardized quality management system has subsystems for medical device production. Facilities that make medical devices are FDA registered and ISO 13485 certified with ISO Class 7 and 8 clean rooms.

We have experience building combination products and getting the necessary approvals for drug-handling services.

Flexible planning for the future

We can help you with sterile assembly automation sized for multi-year demand, as well as a modular approach to final assembly. So you can scale your output as demand changes.