The Stanley Cup Finals are underway, with Boston's Bruins battling our beloved Chicago Blackhawks for the right to the best show and tell item ever. This past year, like most years in Chicago, was characterized by fans eagerly awaiting the beginning of a new season, being disappointed by dismal early-season results and the inevitable realization that the Bears wouldn't make the playoffs, the White Sox/Cubs wouldn't either, and facing the awful truth that Derrick Rose would likely take more shots on a Little Tikes hoop with his baby son than in the United Center in a Bulls uniform.
But we had the Black Hawks. From the very start, this team has been memorable, breath-taking. The 112th minute of last night's triple overtime win was as thrilling the first. It seems like everyone in Chicago is a fan now, many happily ignorant of the significance of blue lines, checks and icing, but eager to be part of the excitement.
For us at Davies Molding, we can't help but be hockey fans because we’re surrounded by hockey reminders every single workday. Look at the pre-forms that become our knobs and handles - they look like pucks to us! Compression molding – thousands of pounds of pressure and hundreds of degrees of heat - turns these little blocks of plastic compounds into knobs, handles, dials and levers. We even do Hawks colors!
So, put on your favorite hockey jersey. (Sorry, hockey experts, we mean sweater.) Find a comfortable chair and enjoy the games. But, when the ref drops the puck, don't forget, sometimes a puck is a lot more than just a puck! Go Hawks!
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 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.
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.
How many years have you worked at Davies Molding? [Scott Hill] 7 years
Prior to Davies how many years have you worked in manufacturing? [Scott Hill] I started in the plastic field March 19th 1984. I first began as a tool room apprentice, then journey man mold maker and then into processing and management. I think the start as a mold maker really helped me understand what was really going on when a part was being produced. Right out of college I worked a year in casting before I eventually started my career in plastics.
What is the biggest challenge of molding plastic? [Scott Hill] Holding the tight tolerances and so many different materials available today
What is your favorite part to mold? Least favorite? [Scott Hill] I can’t really say I have a favorite or least favorite since I’ve been molding custom parts for so long. I can say that I have seen quite a few unique and challenging molds, materials and presses.
Briefly explain how the 2-shot soft touch molding works. [Scott Hill] The mold is set up in a way that you can produce the substrate or base part with one shot while the over mold is being added with another shot. After the mold opens the press will eject the finished parts then rotates so another cycle can begin. One half of the mold is making the substrate while the other half of the mold is getting the over mold to complete the finished part.
What type of press is used? [Scott Hill] There are many different manufactures for multiple shot presses. The obvious is that is must have a horizontal and vertical barrel. Many different materials can be used for the substrate or base and for the over mold as well.
What are the challenges of molding using the thermoplastic elastomer over mold?[Scott Hill] The critical part is making sure the two materials you are using will adhere together.
Comment on this post if you have a question for Scott.
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 .
