Modern climate controlled 20,000 sq foot facility strategically located in Phoenix, Arizona.
Class 100,000 Clean Room.
Hybrid & Electric Molding machines ranging from 40 to 500 tons.
Robotics and Automation integrated into molding process.
ISO certified, GMP compliant, Zero Defect Process Monitoring.
On-site mold making. (EDM,CNC Machining)
SLA support, Prototype, Bridge, and Class A tools.
On-site Quality Department with state of the art Vision Systems.
Engineering services include DFM, Mold Repair & PM’s Programs, DOE, Scientific Injection Molding, Statistical Process Validation, and Product Line Integration or Turn-Key programs. (tool build, machine & automation integrated, process validation then ship to customer)
( The largest reloading manufacturer in the world with
65% of the total market.)
Problem – Poor quality and delivery of outsourced molded components. The main contributing factors were mold damage and excessive flash.
Opportunity – At the recommendation of a colleague, Dillon transferred 144 molds to Icon, which has a reputation for manufacturing high quality precision plastics in the Phoenix area.
Solution – Icon repaired Dillon’s deteriorated tools at its on site mold shop. The tools were processed on Icon’s Electric & Hybrid technology based molding machines utilizing a 28 step Scientific Injection Molding technique.
Results – Dillon experienced a 43% quality improvement. A 20% cost reduction on purchase of molded components due to cycle time and process improvement. An engineering improvement was realized thru repair of Dillon injection molds. Mold up time was improved 40%.
Full service provider – from Engineering to Design to Manufacturing.
Proven track record -- can hit the ground running and can start tomorrow!
Available capacity and machine utilization.
Process variation - Process shifts due to environment changes are eliminated with a modern air conditioned facility and the latest molding equipment.
Technology – Electric & Hybrid molding machines utilize less pressure than hydraulic as a result molds last 20% longer. Molding automation creates consistent cycle times resulting in process repeatability and reliability. Molding machines controlled by process monitors assuring zero defect production.
Scientific Molding – the 28 step procedure provides a wide process window. As a result statistical validation tools can be used to demonstrate process conformance.
Maintenance – On site mold shop to maintain tools and perform ECN’s. Electric & Hybrid molding machines are cleanest in the industry because hydraulic oil usage is minimized.
Time to Market – Efficiency in qualification of tools due to engineering expertise in DFM, Program Management, SIM and statistical tool qualification. Superior design of molding machines leads to 20% uptime improvement over standard machines due to fewer maintenance requirements.
On Going Manufacturing – Systems in place to drive continuous improvement & quality.