The Next Generation of Molders

At Davies Molding, we’ve been designing and manufacturing quality insert-molded knobs, handles, and custom components for over 80 years.  People are our greatest resource, so we’ve partnered with top engineering schools to develop the next generation of innovative thinkers.  Meet Janine Morency, our engineering intern from the University of Texas.  She’s learning hands-on technical and business skills at Davies Molding for a successful future career in manufacturing.  

Please provide a “getting to know you” statement: Where you are from, where you go to school, what you are studying, what is favorite class, etc.

I grew up in St. Charles, IL, and currently attend the University of Texas at Austin, where I’m studying Mechanical Engineering, along with a Business Foundations Certificate. So far, my favorite class was probably Thermodynamics. It was the first mechanical engineering specific class I took and my professor was by far the best teacher I’d ever had. It was both the hardest and most rewarding subject in my college career.

Why are you interested in manufacturing and engineering?

I’ve always liked building things and taking them apart, and throughout high school my advisor pushed me to look into engineering. It was the perfect fit for me. Mechanical Engineering is one of the broadest engineering degrees you can get, with nine tracks at the undergraduate level. Manufacturing is one of the three tracks I chose to look into, mostly because it gives me the biggest opportunity to see problem-solving on a daily basis.

Why did you pick Davies Molding for your internship?

A family friend mentioned looking into the company when I was applying for internships, and as soon as looked around the website I knew it’d be a great fit. I’ve previously taken classes in materials science and drafting, and I knew this opportunity could both help me pinpoint where I want to end up in the manufacturing industry and give me invaluable experience in an interesting field.

How has the internship helped your educational goals and interests?

This internship has provided me the chance to relate the theoretical concepts and ideas I’ve learned to the real world. For example, I’ve studied the difference between thermoset and thermoplastic polymers, but to see the difference in product and manufacturing processes has given me a unique perspective on the subject that I wouldn’t have otherwise had until after I graduated. Like most people, I learn better by seeing and doing things rather than reading it out of a textbook, and I believe this internship will help me greatly in future manufacturing and processing classes.

What surprised you about the internship?

How quickly I picked up on the layout of the machinery on the floor. My first day, I through it would be impossible to navigate around the facility, but by the end of the week I knew where everything was located. This was mostly due to the projects I was given that gave me an inside look at how the different departments and machines operated.

What advice would you give to other students considering an internship at Davies?

Be ready for just about anything! I’ve dabbled in a lot of different aspects in manufacturing that I didn’t even equate with the engineering process. Derran Smith, the president of Davies, also told me to be ready to learn more about plastic knobs than I ever knew existed, and I didn’t realize how right he was. There is so much variation and involvement in the process from beginning to end that can’t be covered in a class or lecture.  Bust most importantly, have fun and learn as much as you can!

Interested in applying for an internship at Davies Molding?  Contact us at info@daviesmolding.com

Hawks Win!

The Chicago Blackhawks are Stanley Cup Champions!  

Every pre-form puck we use this week will be a fantastic reminder of an incredible, record-breaking season.  

Congratulations, Hawks!

A kinder, gentler knob

Ever wish life could be just a little gentler? We do, too. 

So we developed Soft-Touch & Two-Shot Plastic knobs, handles and custom components. They're molded with a soft thermoplastic overmolded top with a tough thermoplastic substrate.
 
It's the best of both worlds. Tough but gentle; offering a non-slip comfortable grip that is durable and resistant to scratches at the same time.  Satisfy your creative urges and pick the sizes, styles and colors that work best for you.  Logo printing and custom finishes are available, too.

  

Why does this matter? Differences in touch and color make identification simpler. Lobed clamping knobs molded with an engineered thermoplastic elastomer and rugged inner core are unique, durable and ergonomic, impacting safety, comfort and performance. And let's not forget style. Glass-reinforced nylon and plastic elastomer two-shot handles not only feel great and last, they look terrific, too. No wonder they're our most popular two-shot handles.

Visit Davies Molding to download our catalog and view technical details. 
350 Kehoe Blvd, Carol Stream, IL 60188 
Call us toll free:  800-554-9208 
info@daviesmolding.com
ISO 9001 : 2008 CERTIFIED

The CAD Man, An interview with Jason Musatto, CAD operator at Davies Molding for 14 years

Briefly explain how the CAD process works. 

The customer will send in a design with specifications or a general design idea. Davies will then review all information and decide on the most economical way to meet the design requirements. I will then generate a 3-D model and subsequently a 2-D drawing that will meet the design requirements and also adhere to molding practices and standards. This design is reviewed with the customer for approval.

What type of programs do you use?

We use SolidWorks, which is a feature-based solid modeling program. We can generate 3-D models and 2-D drawings of part designs and tooling. We also are able to generate 3-D models for direct input into CNC machinery for tool design and models for SLA/stereo lithography proto types.

We also use AutoCAD for generating 2-D drawings.

What is the biggest challenge of creating CADs of plastic knobs and handles?

When reverse engineering a part, getting the design/finished model to look exactly like the original part. Some of the older parts that customers supply to Davies Molding to design for them are from old hand-built molds, before they even had CAD.  The part & mold designs were created with hand drawings, therefore, it is sometimes challenging to match some of the curvature of the design. The end result though is always a functional, ergonomically sound, and seamless design.

What was your favorite CAD project? 

In general, my favorite projects would have to be when customers send in old compression molded parts and want Davies to redesign & manufacture them.  Also any design project that progresses beyond the design, where a mold is built, and parts are manufactured. I also thoroughly enjoy designing Davies proprietary 2-shot design products. The reward for the designer is actually seeing the molded product and knowing the customer loves what we’ve done for them.

To list a few:

Luger magazine end cap - This was a redesign of an old compression molded end cap that fit into the end of a magazine for a German Luger pistol. There were many tweaks along the way to get the part to look exactly like the original, but when the project was finally complete, you could not tell the difference between the Davies redesign and the original.

Fan knob – Another old compression part redesign for Vintage Fans. It was a switch control knob for a ceiling fan. The redesign was very challenging, but very rewarding. The end product looked great and the customer loved it.

Water tank – A food equipment manufacturer wanted us to redesign a water tank that was made from sheet metal into a plastic one. This was an extensive design process but resulted in a great functional product that the customer loved. The best part was the money we saved the customer in converting a sheet metal part to plastics.

How is CAD used effectively in Davies’ manufacturing process?

CAD is most effective in manufacturing because of its ability to make quick changes to models/drawings. Models and drawings are associative, so changes to designs are quick and easy. Most importantly, this allows the manufacturing process to flow smoothly without potentially costly interruptions.

Davies Molding Celebrates 80 Years of Success - An interview with its President, Derran Smith

As Davies Molding LLC enters its eighth successful decade, President Derran Smith reflects on key issues and looks forward to a future that he believes is full of promise for the plastics molding company.

What distinguishes Davies in the industry?

[Derran Smith] Davies Molding has a very strong brand image for plastic knobs, handles and custom molded products in the marketplace.  However, it is also well positioned to service all of its customers’ plastics needs from creative generation, new product development, mold design, mold flow analysis, tooling build, first article sampling, etc..  Being one of the few molders that are efficient in Compression, Injection and Transfer molding, we offer a much wider range of custom molded services and materials to our customers.  Also, we provide an extensive array of secondary/finishing operations after molding such as drilling, tapping, laser engraving, branding, pad printing, chrome plating, etc…  – basically whatever our customers need.

How does an eighty year old company stay competitive and continue to be relevant to its customers?

[Derran Smith] We are determined to stay competitive and meet the plastics needs of our customers.  We benchmark ourselves not only against our competition but against best practices from leaders in other industries.  If there is an identified opportunity for improvement, we put a plan in place to achieve that goal.  Lastly, we evaluate our progress to make sure actions put in place are working.  The most important aspect in all this is listening to customer requests and responding to needs in the marketplace.  It certainly helps to have a well established and loyal customer base to draw ideas from.

What does Davies Molding want to achieve in the next 10 years?

[Derran Smith] Over the next several years, Davies Molding is positioned for growth.  We will continue to invest in new products and capital equipment to support the current line of knobs, handles and cases.  At the same time, we will be looking to vertical integrate either by internal growth or through acquisitions. 

Company and product information can be found at www.daviesmolding.com or emailing us at info@daviesmolding.com

We welcome your comments!  Please post a comment on our blog or contact us directly.

New to knobs? Here’s an infographic that might help

Molding a control knob for your alma mater!

Go beyond the typical university sweatshirt and show your pride by choosing a control knob that features your school colors.  Are you an Ohio State or Notre Dame grad?  We've got colors for you!  With Notre Dame heading to Florida to play in the BCS title game on Jan. 7, we think we'll be molding a lot of blue and gold knobs for those engineering fans!

TWO SHOT & SOFT TOUCH COMPONENTS CAUSE DAVIES MANIA!

Davies' two-shot and soft touch knobs, handles, and custom plastic components are molded with a soft thermoplastic overmolded "rubber" top with a tough thermoplastic substrate and are available in a variety of sizes, styles, and color combinations to make your products stand out!

To find out more about Davies' two shot soft touch products or about any of our standard products visit www.daviesmolding.com or check us out at .

Davies Molding LLC "A Manufacturing Marvel" as Featured on Fox Business News 'Manufacturing Marvels'

 

http://www.youtube.com/watch?v=RPY4EsZaWN0

Davies Molding, LLC to be featured on Manufacturing Marvels (tm)

Davies Molding, LLC is proud to participate in a 2 minute production called Manufacturing Marvels™, a weekday broadcast on the Fox Business Network.  The segment, hosted by John Criswell, will be aired on Monday, April 9^th, 2012 at approx. 8:30 PM-8:40PM Central Time. Manufacturing Marvels™ spotlights leading American manufacturers, their products, and processes.

We are honored to participate in Manufacturing Marvels™.  Davies Molding was contacted by Marvel Production Group, LLC for participation because it is recognized as a leading manufacturer of plastic knobs, handles, cases & covers, and custom plastic components with particular specialty in insert molding through both injection and compression processes.  The production will highlight Davies Molding’s manufacturing capabilities, engineering, CAD design, and secondary/finishing capabilities such as laser engraving, drilling, tapping, assembly, pad printing, hot stamping, branding, bagging, and sand blasting to name a few.

The generic time slot on most TV listings will be from 8-9 on FBN.  We are expecting the actual broadcast between 8:30-8:40 PM.  Channels will vary due to content providers and geographical markets, but the local Comcast channels are 106 (Standard Definition) and 264 (High Definition).  So turn your dial and set your DVRs.