Process Model

A clear path from concept to production — with fewer surprises along the way

Every injection molding project follows a series of critical decisions that affect cost, quality and timeline. R&D Plastics has spent more than 30 years refining this process to help customers move from a CAD file to finished parts as efficiently as possible. Our model is designed to surface potential issues early, keep communication clear and reduce the risk of costly changes downstream.

Here’s how a typical project moves through our process:

Phase 1: Planning & Quoting

Before anything is built, we work with you to understand the full picture — what your part needs to do, how it will be used and what success looks like. This upfront collaboration sets the foundation for every decision that follows.

Understanding the Application

All of the application requirements for your part should be defined early: cosmetic, dimensional, functional and environmental. These requirements guide part design and material selection.

MATERIAL SELECTION

Based on those requirements, we help identify the right material. It’s important to select the material before finalizing the part design, because different materials have different design guidelines.

QUOTING THE PART

We can provide a part quote based on anything from an early sketch to a fully detailed CAD file with tolerances and quality specifications. The more detail we receive, the more accurate the quote. When comparing quotes, ask each supplier for key assumptions — we’re happy to share ours.

PART DESIGN & CAD ASSESSMENT

A CAD file is the most accurate and economical starting point for building a mold. It can also be used to create prototypes and evaluate the part visually and functionally. We can give design-for-manufacturability feedback on your CAD model and review any subsequent refinements.

PROTOTYPING

There are several prototyping methods, from machined parts to prototype molds. The right approach depends on how you plan to use the prototypes. We can help determine the best option for your project.

QUOTING THE MOLD

Using the CAD file, we provide a mold quote based on the design that will produce the highest-quality part at the best value. If you’re comparing quotes from multiple suppliers, we recommend confirming that each quote reflects the same mold quality. We can provide a specification sheet to help with that comparison.

Phase 2: Tooling & Design Review

With planning complete, the focus shifts to mold design and construction. This phase involves close collaboration between our team, the moldmaker and your engineers to make sure the tool is built right the first time.

MOLD DOWN PAYMENT

Standard industry practice is to require a down payment, ideally submitted with the purchase order and final CAD file. Our terms are 50% down, 40% on delivery of the mold and 10% on part approval.

MOLD DESIGN REVIEW

This meeting covers the final, detailed mold design. Customer attendance is preferred.

PART DESIGN REVIEW

We assemble the customer, molder, moldmaker and any other relevant parties — such as the material supplier or mold texturer — to confirm that the part design is compatible with the proposed mold design. Together we review a detailed checklist and establish a project timeline.

MOLD CONSTRUCTION

Questions often come up during construction. Our approach to handling them is established during the Part Design Review, and answers are documented. If you request a design change during this phase, we’ll provide a quote for the modification and any impact to the delivery timeline. The next 40% of payment is due upon delivery of the mold.

Phase 3: Testing & Approval

Before production begins, we verify that the mold performs as expected and the parts meet your specifications.

MOLD TESTING

We recommend a level of testing based on part complexity and your quality expectations. Testing verifies that the mold can consistently produce parts that meet requirements.

PART APPROVAL

Once the part meets all specifications, we approve it for production. This approval should be documented in writing, and the final 10% mold payment is due.

MOLD MODIFICATION (IF NEEDED)

If changes are needed after the first mold test, the final 10% mold payment is due before modifications begin. You’ll receive a quote for the modification along with any additional testing costs.

Phase 4: Quality Standards & Production

With an approved part in hand, we establish quality standards and prepare for production.

WRITING QUALITY STANDARDS

Using parts and data collected during testing, our Quality Manager creates work instructions for operators and inspectors. Quality Control assembles a complete part book with all relevant documentation.

PRODUCTION

The first production order triggers installation into our Material Requirements Planning (MRP) system. We establish delivery dates based on material lead times and machine workloads. Customers often submit the first production order alongside the mold purchase.