Injection molding and tooling services

EnCata provides injection molding and tooling services. We manufacture injection molds, test injection mold tooling, prototype tooling, and support mold tooling production. Mold companies specialize only in plastic or silicone injection molding, while we provide all these services.

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Custom plastic tooling and design optimization

The design of the injection molds is one of the final steps in new product development. The product must be ready for mass production. Plastics and other polymers are characterized by the high tooling cost and the considerable time required for tooling production. This technology is not rational for small batches of a product. Therefore, it is important to begin tooling production only after making sure that the design is practicable, after optimizing the parts in terms of shape, weight, and design.

When making the design, we consider other components like PCBs, batteries, sensors, etc. We make mathematical calculations of the mechanical characteristics of the parts. Spillage calculations will be useful for complex parts to simulate the part production process and reduce the risk of getting defective products.The plastic parts should be optimized for the injection molding process. We work on it at the design for manufacturing (DFM) stage. In this case, DFM is based on selected material, manufacturing constraints, and the planned production volume. After DFM, you evaluate the cost of injection molding tooling. 

60+ Engineers

We act as your extended R&D team which is faster than hiring engineers locally. The breadth of our technical expertise is unique.

Development Speed

Our dedicated team is ready to scale up quickly. We utilize AGILE lean development process that leads to 30-50% faster delivery.

Burn rate

Cost-effectiveness

Our development location enables us to be cost-effective and deliver premium R&D and engineering services at 1/3 of the price compared to that of in N-W Europe and USA.

Prototype before injection mold tooling

We know how certain design decisions can complicate production and increase the cost of the production preparation. It is possible to design a good but over-engineered product that will require large investments in the pre-production process. 

We prototype a product by 3D printing or machining engineering plastics during DFM to test our ideas. We manufacture pilot batches of prototypes at the final stages using the injection molding machine. We prototype tooling or do rapid tooling to provide injection molding services for low volume production. EnCata is not an OEM company, but we recommend proven specialized plastic molding companies or plastic parts manufacturers and provide you manufacturing support.

mechanical engineering DFM

Mechanical Engineering

Our team ensures that our customers’ products are competitive and safe and that their life-cycle corresponds to our customers' business plans.Our engineers will design the product to meet your plastic injection molding process requirements. If you already have a prototype, they will advise on the options for its refinement or functionality expansion, build 3D models based on your sketches and make drawings to digitize your idea.

Industrial Design

The industrial design of a new product must be attractive and user-friendly. However, in addition to the external characteristics of the product, the industrial design considers the production process and prototyping strategy. When the production stage comes, it will significantly reduce the costs for injection molding services.In addition, an industrial design must make a sale. Often we get projects with designs that make the product uncompetitive in price in the market segment.

Enclosure Design

Most modern products have electronics that are protected by enclosures. Furthermore, the user interacts with the device through the enclosure. At different stages of new product development, product enclosure requires different technologies for prototyping.Sometimes, it is possible to start sales with a standard enclosure. It has to be decided based on an analysis of the product, the business model, user expectations, and the manufacturing capabilities.

Proof-of-Concept Prototyping

Our experience shows it is always better to test an important hypothesis for a product as early as possible. The development of POC is different from the development of a final product. POC is a demonstration involving creating a small prototype, test sample, mathematical or computer model, not necessarily a complete product (which distinguishes a proof of concept from a minimally viable product), but confirming the real possibility of its creation. It is critical to understand both the business objectives and basic engineering principles and the skill to carry out experiments.

Custom electronics design

Electrical Engineering

EnCata provides PCB design and industrial electrical engineering services. We can design and manufacture a PCB, develop firmware, design an automation system and program a controller, design a power supply system for a robot or battery management system for a drone.We provide a complete combination of all product modules. All elements are designed in combination, including printed circuit boards, operating modules, and enclosure parts.

Manufacturing Support & Sourcing

We do not manufacture thousands of molded plastic parts. We can provide the Client with information on how to organize mass production. If you have finished designing and want to start mass production, we can recommend a production company. We will assign an engineering team that specializes in plastic injection molding. They take care of communicating with the manufacturer and solving quality issues. In addition, we can provide support and assistance to production at all stages of its organization.

Custom plastic molding can be break even

Injection molding is a manufacturing process for producing parts in large volumes. It is most often used in mass production processes where the same part is created thousands, or even millions of times successively.Injection molding manufacturing process requires a good amount of investment to start mass production. The preliminary analysis of the product reduces the cost and duration of molds manufacturing. Before you endeavor to produce a part via injection molding it is reasonable to consider things like entry cost, production quantity, design considerations, assembly, etc.

Our engineers and designers work to reduce material waste and parts quantity in order to make the manufacturing process more cost effective and to reach a break even point on your investment. The main goal is to optimize design for injection molding. Smart plastic part design can result in a 25-30% cost-reduction of injection molding and production tooling.

How To Start Plastic Injection Molding With EnCata?

Usually, Clients come to us with a prototype assembled from standard modules and a printed enclosure. EnCata’s task is to develop an injection mold for the product’s plastic parts. In this case, before the mold design, we refine the Client's requirement and adjust the product design for molding. We also make technical and economic calculations to select proper injection molding plastic.

If the Client comes to us with an idea, we add the development of a prototype to the activities described above. We extend the scope of work by creating an industrial design, developing a 3D model, computer modeling of the injection process, assessing the ergonomic design, and, if necessary, making 3D prototyping of the product.

Product Development Technology Stack

Two-shot injection molding
Molding of elastomers

Shrinkage calculation
Molding simulation
3D-printing

Plastic selection
Aluminum molds
Vacuum forming
Molding in silicone forms

Plastic parts
Ingection molding
Molding in silicone forms

Durability
Vibrations
Kinematics

Plastics
Rubbers

Engagement Models

We focus on the entire product lifecycle, from concept to implementation and market launch. EnCata's knowledge, resources and experience in innovation enable our clients to bring a product to market with minimal cost or time.

Some hardware Projects we delivered

Work that highlights the incredible technologies, solutions, and products EnCata developed.

Industries We serve

Our hardware engineers are focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

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