Litigation-Informed Design
Understanding why plastic parts fail is key to designing, developing, and manufacturing reliable products. Our failure analysis background gives us an advantage in preventing the exact failure modes we've seen in courtrooms.
Polymer Science, Not Just Form
Our plastic experts understand the chemistry and engineering of plastics at the molecular level. We don't just design shapes — we engineer materials, crystallinity, and additive packages for real-world performance.
Decades of Manufacturing Experience
Our team has decades of hands-on experience in the Plastics Industry. We've successfully helped many clients bring their ideas to market rapidly and cost-effectively.
Early Retention Saves Millions
Experienced plastic experts have seen it all and know the pitfalls. Early retention of a highly experienced plastic engineer speeds up the development process and reduces cost — we helped one client save millions through optimized die design alone.
Quality Control System Development
Residual stress in plastic parts is often a key factor causing failure. The fabrication process should be carefully optimized to minimize residual stresses. We develop simple, effective tests for accepting or rejecting parts — like oven-based dimensional change measurements — to detect residual stress before parts leave the factory.
Cost Reduction Consulting
Cost is directly related to resin cost and production rate. Some products are over-engineered with expensive plastics when a lower-cost alternative works equally well.
Dynamic FEA & Supercomputing
Our dynamic computer simulation expert uses high-speed supercomputers to predict the fatigue performance and service life of plastic parts. Very few design firms have this capability.
Packaging
Plastic Storage Bag Die Design
Used dynamic die modeling technology powered by high-speed supercomputers to design extrusion dies for different size bags. The dies performed flawlessly. The client told us we saved them millions.
Plumbing / Consumer
Toilet Flush Valve Failure Analysis
Glass-fiber reinforced PP flush valve failed in service. SEM revealed fiber orientation parallel to fracture. Mold flow analysis confirmed improper gate location caused the fiber alignment issue — proving a design/mold defect.
Manufacturing
Residual Stress Reduction Program
Developed quality control protocols for detecting residual stress using oven-based dimensional change measurements. Optimized fabrication processes to minimize stress, reducing field failure rates.