A global manufacturer approached Underwood Mold Company with a challenge: improve their modular injection-molded base pans to simplify the existing configuration and improve production efficiency. The objective was clear—reduce time and labor costs while maintaining strict engineering standards.
Leveraging our expertise in wire electrical discharge machining (EDM) and innovative mold development, Underwood engineered a new snap-fit configuration that streamlined assembly of both parts and components. This improved configuration significantly reduced assembly time and associated labor costs.
Before committing to full-scale production tooling, we built experimental tooling to validate the new snap-fit concept. This allowed us to test, refine, and prove performance and durability in real-world conditions. Once validated, we moved forward with the development and fabrication of production tooling.
Working closely with the customer’s product engineers, we met dimensional tolerances as tight as 0.001 inches. To ensure continued compliance, our toolmakers provided detailed mold dimensional reports. After production launch, we performed ongoing dimensional checks along with fit-and-function testing at scheduled intervals throughout each production day to maintain quality standards.
Underwood’s high-volume production capabilities also supported a seamless transition from the obsolete base pans to the updated model. With the capacity to produce millions of units annually, we maintained a weekly turnaround for parts and held tooling lead times to just 8–10 weeks. Through careful engineering, testing, validation, and precision machining, we delivered a cost-effective solution that met performance expectations and stayed comfortably within the client’s budget.
This project represents just one example of the collaborative expertise Underwood Mold Company brings to every partnership. Since 1969, we have been a trusted provider of high-quality injection molds and molded products. We welcome the opportunity to help you develop innovative solutions that enhance efficiency, reduce costs, and strengthen your operations.
Contact us today to learn how we can support your next project.
