Case Studies of Our Custom Injection Molding

At PolyFlex Products, we want to help make a finished project with our custom injection molding that fits your vision. Whatever materials you need to safely transport, it is our desire to help you reach that goal. With our expertise in dunnage engineering, thermoforming packaging, and injection molding, we have left many clients satisfied with their finished product. To see some of our prior work and learn the thought process behind each, click the links below.

In-Process Packaging: Valve Body Baskets

In-process fixtures for transporting raw and fully machined transmission valve bodies through an OEM’s machining centers.  The fixtures must contain the parts within a tight tolerance, keep the parts separated, and protect the parts from damage during the process.

Returnable Packagiing: Engine Rack Vibration Dampening Puck

Returnable racks for shipping fully assembled engines from the OEM’s engine plants to the assembly plants. The racks must protect the parts and keep the engines nested in the racks during the transportation process.

Expendable Packaging:

Free Floating Dunnage: Transmission Pack

PolyFlex® engineered free-floating dunnage inside commercially available collapsible plastic bins for housing and shipping a wide range of finished transmissions to assembly plants all over the globe saving the automotive manufacturer over $17 million during the life of the program.

Returnable Packaging:

Crank Case Tray

PFP produced high precision, pallet-sized returnable trays with accuracies and strength needed for robotic handling by integrating the economies of vacuum forming with the strength and precision normally associated with more expensive injection molding processes.

Shipping Rack:

Truck Bumper Dunnage

Thermoset urethane vibration dampening boots eliminated the need for two nesting posts and the damaging effects of dislodged bumpers during transit while reducing labor costs for unloading and providing the automotive OEM with $550,000.00 in dunnage savings.