Manufacturing Insights: From Material Selection to Final Assembly
Stop searching for fragmented solutions. Your complete manufacturing partner is here.
We offer end-to-end engineering solutions backed by decades of expertise that accelerates your product lifecycle. From the moment of initial design conception to the delivery of a fully assembled final component, we can guide your every step.
Leverage our deep knowledge in engineering plastics, precision mold design, tooling and mold manufacturing, and dedicated assembly services to transform your concepts into reliable, market-ready products.
1. Two Pillars in Engineering Plastic
In industrial manufacturing, particularly in polymer (plastic) molding, thermoset and thermoplastic are two distinct categories of engineering polymers. These polymers are differentiated based on their thermal behavior, their manufacturing processes, their recyclability, and their electrical and mechanical characteristics once the polymer is transformed into its final shape. These distinct characteristics enable us to develop products by selecting the appropriate polymer based on their application in the real world.
Thermoset Polymers
Thermoset polymers are a type of engineering polymers that create strong cross-linked bonds when subjected to a combination of heat and pressure, either with or without the presence of a catalyst. This three dimensional polymer cross-linking process, which causes the polymer to set in its final shape, is known as curing or polymerization.
Once cured, these cross-linked bonds cannot be altered or recovered, and the material turns rigid. Meaning, the chemical change that a thermoset polymer undergoes is irreversible. The polymer cannot be recovered or recycled by application of heat, as is the case with thermoplastic polymers. Sustained application of high temperature on parts made using thermoset polymers will result in the product burning or charring (like coal), rather than the polymer melting.
These chemical properties make thermoset polymers an excellent material of choice in parts that are required to maintain their dimensional stability when subjected to mechanical, electrical, and thermal loads.
Advantages of Thermoset Polymers
The unique cross-linked structure and properties of thermoset polymers give it numerous advantages.
-
Mechanical Strength: Thermoset polymers have excellent strength-to-weight ratio and rigidity, which can be enhanced by the addition of glass or carbon fiber reinforcements.
-
Electrical Resistance: Thermoset polymers display excellent electrical insulating properties along with low thermal conductivity.
-
Chemical Resistance: The strong cross-linked bonds give thermoset products excellent resistance to most solvents, chemicals, and moisture.
Applications of Thermoset Polymers
The advantages of Thermoset Polymers make it a resin of choice for numerous demanding industries and applications. Our Thermoset molded components are most commonly used in the industries listed below.
-
Electrical Infrastructure: Products such as electrical switchgears, molded case circuit breakers (MCCB), air circuit breakers (ACB), insulating covers for motor and stators, and terminal blocks utilize the advantages of thermoset polymers to ensure that the products and consumers are safe from current leakage and heat build up.
-
Automotive, Locomotive, Aerospace, & Defense: Thermoset polymers ensure that critical components within automotive, locomotive, aerospace, and defense equipments can operate under high thermal & electrical conditions while maintaining their structural integrity for smooth and reliable operations in critical equipments.
-
White (Consumer) Goods and High Heat Appliances : White goods industries (washing machines, refrigerators) such and high heat consumer appliances (ovens, toasters, electric irons, kettles, and cookware handles) rely on the electrical and thermal insulating properties of thermoset polymers for safe consumer operation of home equipments without any heat or current transfer.
Thermoplastic Polymers
Thermoplastic polymers are a type of engineering polymers that create linear or branched polymer chains when subjected to a combination of heat and pressure, either with or without the presence of a catalyst. These polymer chains have relatively weak intermolecular forces when compared to the complex three dimensional cross-linked structure formed by thermoset polymers.
Once cured, products made using thermoplastic polymers can be altered and recovered, even after the material has turned rigid. Application of heat on thermoplastic products will break the weak intermolecular forces causing the thermoplastic to melt (similar to heating a stick of butter).
Thermoplastic polymers can undergo repeated heating and cooling cycles to melt, reshape, and reuse the polymer numerous times without significant impact to its material properties. Scrap generated from thermoplastic molding can be recycled by regrinding and remelting it for future applications.
Parts requiring high volumes, high recyclability, and impact resistance benefit from the material characteristics of thermoplastics. Add to that, the material molding and processing of thermoplastic is much less complex than thermoset polymers and there is minimal to no post processing required on the final product.
Advantages of Thermoplastic Polymers
The linear/branched chain structure of thermoplastic polymers and recyclability under heat give it numerous advantages.
-
Impact Toughness: Thermoplastic polymer chains have good impact toughness as their bonds can absorb impact loads without breaking under impact stress.
-
Recyclability: Scrap (from runners and gates) and defective products made using thermoplastic polymers can be reground and reused multiple times. This makes thermoplastic an excellent choice for sustainable manufacturing using plastics by ensuring zero waste from the process is disposed to landfill or the environment.
-
Aesthetic flexibility: Thermoplastic can be easily processed in a variety of colors, surface finishes, and appearances making it a versatile polymer to meet a wide variety of aesthetic requirements.
-
High Volume Production: Ease of post processing and fast curing times for thermoplastic components improves manufacturing speed resulting in low-cost production of high volume parts.
Applications of Thermoplastic Polymers
The flexibility, recyclability, and ease of processing inherent in thermoplastic polymers make them the workhorse material across numerous high-volume and consumer-facing industries. Our thermoplastic molded components are most commonly utilized in the industries listed below.
-
Automotive & Transportation: Superior impact toughness and versatile surface finish make thermoplastic ideal from vehicle trims, panels, caps, and other accessories in automotive and transportation industries
-
Electrical and Consumer Appliances: Ease of high volume production and versatile color and surface finish capabilities make thermoplastic the material of choice for aesthetic surfaces on a large number of electrical and consumer appliances.
Plastic Molding Process
Injection Molding: The Screw & Barrel System
We operate two distinct injection setups to accommodate the vastly different thermal requirements of polymers.
Thermoplastic Injection
-
The Physics: Material is melted in a high-heat barrel and injected into a cooled mold, where it solidifies.
-
The Equipment: Standard reciprocating screw machines optimized for rapid cycles.
-
Best For: High-volume production of complex, high-impact components.
Thermoset Injection
-
The Physics: Material is kept in a state of "flow" within a water-cooled (chilled) barrel to prevent premature curing. It is then injected into a high-heat mold (150-180 degree Celsius) to trigger the chemical cross-linking.
-
The Equipment: Specialized injection units with precision-controlled barrel cooling systems.
-
Best For: Automated, high-volume production of heat-resistant electrical housings and MCCB components.
Transfer Molding: The Precision Pot & Plunger
For projects requiring delicate metal inserts, we utilize the Transfer process to ensure zero component displacement.
-
The Mechanics: A pre-heated thermoset "biscuit" is placed into a transfer pot. A hydraulic plunger then forces the material through runners into a closed, heated mold.
-
The Advantage: Since the mold is closed before the material enters, there is no high-pressure "blast" of material that could bend or move internal copper/brass pins.
Compression Molding: Direct Charge Placement
The standard for high-strength structural parts using BMC/DMC (Bulk/Dough Molding Compound) or SMC (Sheet Molding Compound).
-
The Mechanics: A precise charge weight of material is placed directly into the open, heated mold cavity. As the press closes, the material is compressed into the final geometry where it cures under applied heat and pressure.
-
The Engineering: We focus on fiber-length retention. Because the material is not forced through small gates, the internal glass fibers remain intact, providing superior mechanical strength.
2. The Manufacturing Ecosystem
Creating a product is more than just selecting the right material. It requires a chain of engineering excellence, from design to the final tool.
Engineering Excellence:
Mold Design & Design for Manufacturability (DFM)
From Design to Final Tooling
Mold design and DFM are critical stages prior to commencing molding production. The investment required to manufacture the tool is usually significant in comparison to the cost per molded part. Mold design and DFM ensure that the products can be made in a cheap and reliable manner without future corrections to the molding tool.
DFM is the foundation of high-quality, cost-effective manufacturing. It involves optimizing a design to guarantee successful, repeatable production. Our engineers specialize in:
-
Draft Angles: Essential wall tapering that allows the part to eject cleanly from the mold.
-
Wall Thickness Control: Maintaining uniform thickness to ensure even cooling/curing, preventing warpage and sink marks.
-
Gate and Runner Optimization: Strategic placement of material entry points to ensure optimal material flow, cosmetic quality, and structural integrity.
Precision Machining: Our Technical Edge
Our Tool Room is equipped with state-of-the-art machinery capable of meeting the tightest tolerances required for complex molds and components:
-
CNC VMC (Vertical Machining Centers): Multiple advanced CNC VMCs ensure high-speed, high-precision milling of complex 3D mold cavities.
-
EDM (Electrical Discharge Machining) & Super Drilling: These capabilities allow us to machine intricate shapes, deep cavities, and extremely hard materials that conventional cutting tools cannot touch. Spark erosion (a form of EDM) is essential for creating fine details, sharp corners, and specialized features in the mold steel.
-
Surface Grinders: Precision surface grinders ensure flawless flatness and parallel accuracy on mold plates and components, which is critical for preventing flash and ensuring uniform clamping pressure.
This internal machining infrastructure ensures that all types of components, molds, and tolerances can be met efficiently and reliably.
Benefits of Our In-House Tool Room
This capability provides two major, competitive advantages to our clients:
-
Quality Control and Precision: We oversee the material selection (steel/aluminum) and precision cutting of every tool, ensuring adherence to tight tolerances. Crucially, our mold makers design and build tools while keeping in mind the precise operating parameters and capabilities of our own molding machines, ensuring the mold runs at peak efficiency from Day One.
-
Uninterrupted Production: Our dedicated tool room enables us to perform immediate maintenance, repairs, and engineering changes (ECOs). Eliminating reliance on external vendors drastically minimizes production downtime and keeps your supply chain reliable.
Mold Manufacturing & The Dedicated Tool Room
3. Integrated Solutions: From Component to Complete Product
At Raman Thermosets, we believe our job isn't finished until the product is ready for its final application. While many manufacturers only provide loose components, we offer dedicated assembly lines designed to deliver fully assembled, turnkey solutions.
Dedicated Assembly & Secondary Operations
Fully Integrated Assembly Services
We bridge the gap between raw molding and the final product by managing the entire assembly lifecycle under one roof. Our assembly lines are equipped to handle:
-
Component Integration: Installing electrical contacts, moving mechanisms, metal inserts, springs, gaskets, accessories and covers.
-
Secondary Operations: Precise mechanical fastening, adhesive bonding, welding, punching, crimping, and manual checking.
-
Testing & Quality: Implementing in-line testing to ensure that every finished unit meets its functional specifications before it leaves our facility.
By choosing an integrated assembly solution, you simplify your supply chain, reduce logistics costs, and ensure a single point of accountability for the quality of the final product.
The Assembly Challenge: Tolerance Stack Up
One of the most critical challenges in manufacturing multi-part products is Tolerance Stack-Up.
The Problem: Every part has a small, acceptable variation (tolerance). However, when five or six parts are assembled together, those tiny variations can "stack up." If Part A is at its maximum limit and Part B is also at its maximum, the final unit may no longer fit into its housing or may fail to operate correctly leading to assembly failure.
Our Solution: At Raman Thermosets, we own the execution of all products assembled on our shop floor. We ensure every part is made to your exact specification using:
-
Incoming quality control: We employe incoming quality inspection on all parts for a given assembly line to ensure only acceptable components are delivered to our assembly line
-
Custom Checking Fixtures: Precision jigs designed for your product to verify geometry and fitment as per your specification. These can be produced rapidly with our in-house tool room.
-
Go/No-Go Gauges: Real-time tools used on the production floor and our incoming quality room to guarantee 100% fitment for every batch.
-
Rigorous Testing: We perform both sample based and 100% testing on our assembled products which simulate real world scenarios to ensure the devices we assemble perform as intended.