The Extreme Molding Manufacturing Process

A partnership with Extreme Molding is unlike any other silicone products manufacturer. Our personal approach, full-service model and proprietary manufacturing process are designed to ease the transition from prototype or foreign-made product to successful, made-in-the-USA product.

Our process always starts with a quick, friendly reply to your first inquiry. From there, we will follow these steps:

1. Evaluation

We will require a CAD file to determine if your product is a match for our unique skill set. We are always happy to sign a non-disclosure agreement to protect your intellectual property.

2. Estimation

You can expect preliminary cost estimates within hours of our first conference call, and final numbers in about two days. Transparency is important to us, so we will break down the cost of materials, labor, packaging and overhead and disclose our expected profit margin.

3. Problem Solving

Our engineers will consult with your team to design your product for large-volume manufacturability without compromising function or visual appeal.

4. Material Selection

We are experts in a wide range of specialty silicones, and will work with you to select the right materials to meet your product’s performance, durability, safety and regulatory requirements.

5. Sourcing your Mold

We have a strong relationship with our mold-making partners, most of which are in New York State, and will be actively involved in the design process to ensure your mold meets our exacting standards. Expect six to eight weeks for mold construction. We ask that mold costs are paid 50 percent up front, with the balance due after first article’s approval.

6. Package Design

We are experts in a wide range of specialty silicones, and will work with you to select the right materials to meet your product’s performance, durability, safety and regulatory requirements.

7. First Article Approval

Once we have your mold, we will produce parts for first article approval and issue a report comparing your specifications to those of the molded components. Any issues will be addressed immediately. If all is well we will move into full-scale production.

8. Production

We have over 50 team members working three shifts, seven days a week. We are flexible, responsive to your requests and accustomed to tight schedules. Our minimum order requirements are quite reasonable.

9. Secondary Operations and Assembly

We perform a wide range of secondary operations in-house, including:

  • Application of medical adhesives to molded parts
  • Pad printing of silicones and plastics
  • Ultrasonic welding in a Class 100,000 white-wall environment
  • Die-cutting
  • Assembly
  • Cryogenic Deflashing

10. Packaging and Fulfillment

Finished products will be thoroughly inspected, then packaged in our white-wall room and prepared for shipment to anywhere in the world. We will route trucks to retail stores or distribution centers or process orders and ship to individual customers via U.S. Mail, UPS or FedEx.

Launch a Product

If you have a great idea, we can help bring it to life. We’ve done this before and enjoy becoming partners throughout product creation. From advising you through the mold sourcing process, to delivering your new product to customers, we want to work with you every step of the way.

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