Injection Molding

United Support Solutions-LMT, Inc.’s injection molding facilities (known an LMT Products) are located in Lawrenceville, NJ and Akron, OH. Together they house 42 state-of-the-art plastic injection molding machines ranging from 85 ton to 720 ton and with full robotics.

Each plant is fully staffed with seasoned plastic engineers with prototyping capabilities. From concept to final product, our engineers oversee the entire process. We offer MoldFlow computer analysis for optimal mold design. Each plant also practices Scientific Molding to ensure superior cycle efficiency. Our plants are ISO 9000 certified, and audits are performed each year. United Support Solutions-LMT, Inc. is fiercely committed to quality and known for their “speed to market.” Each plant also offers secondary operations such as ultrasonic welding, hot stamping, specialty packaging. Our Hartville plant is also equipped to do powder coating of plastic thermoset materials and dye sublimation.

Prototyping

LMT has in-house 3D printing capabilities. Having this technology in-house can greatly reduce time to market. Most prototypes can be printed same day, allowing multiple revisions to be completed in a week. Before using this technology, these changes would need to take place with the tooling steel that would increase the very valuable time to get new products to market.

LMT has two printers that utilize different technologies.

Stratasys Dimension 1200es

  • Fused Deposition Modeling (FDM)
  • 10″ X 10″ X 12″ max build size
  • Layer thickness down to 0.010″
  • Prints material similar to ABS mechanical properties
  • 9 different colors available

Stratasys Objet30 Pro

  • PolyJet modeling technology
  • 11.5″ X 7.5″ X 5.9″ max build size
  • Layer thickness down to 0.0006″
  • Multiple materials available
    • Rigid material in 4 colors
    • Clear material similar to PMMA
    • High temperature for functional testing
    • Simulated polypropylene great for testing snap fit features

Scientific Molding

Until recently, injection molding was thought of as more of an art than a science. Times have changed. Scientific injection molding (SIM) is a highly technical, scientific approach to developing and optimizing an injection molding process. It follows a standardized, data-driven methodology to plan and collect important information about the molding process. United Support Solutions-LMT, Inc. uses Scientific Injection Molding procedures in order to consistently produce identical parts, time after time, machine after machine, and set-up after set-up.

Mold-Flow

United Support Solutions-LMT, Inc. uses computer-aided engineering plastic flow simulation software to improve the quality of the molds we build and the parts we make. We don’t wait for the mold to be built and tested to discover a problem – we detect and prevent potential issues in the design stage.

The combination of Moldex3D software and our experienced engineers allow us to reliably determine:

  • Proper part design
  • Ideal location of the gate(s)
  • Weld line locations
  • Sink mark locations
  • Gas trap locations
  • Required injection pressure
  • Required machine tonnage
  • Imbalanced family molds
  • Mold cooling efficiency
  • Potential part warpage
  • Estimated cycle time

Dye Sublimation

United Support Solutions-LMT, Inc. can also provide decorative wood grain effects to products by a sublimation process. Using pressure and heat combined with this two-step process produces wood grain finishes.

In the first step, products are powder-coated the same way that our regular parts are, except that special powdered paint designed for dye sublimation is used. The second step is dye sublimation.

Once the parts are powder-coated, they are loaded onto fixtures on the surface of a trolley table. A pre-printed transfer film is laid on top of the parts. The trolley is placed within a specialized oven where the transfer film is heated slightly to make it flexible enough to conform to the 3D shape of the parts. An integrated vacuum suction system removes the air between the film and the parts.

With the trolley still inside the specialized oven, ink pigments in the transfer film are converted from a solid, into a gas, and back again to a solid within the powder-coated paint layer. This process takes about 10 minutes. In the last step of the powder-coat process, the film is removed upon cooling, leaving a decorated part that is protected against factors such as weather, corrosion, abrasion, UV light, and humidity.

Powder Coating

United Support Solutions-LMT, Inc. can provide finishes using custom-designed colors, looks, and textures on plastic parts.

With the use of electrostatic guns, a layer of non-hazardous powdered paint is applied to a preheated proprietary plastic substrate. The powder-covered parts are then transferred into a 400°F oven for up to 30 minutes. This cures the powdered paint into a hard, durable finish. Additionally, it protects the final product against factors such as weather, corrosion, abrasion, UV light, and humidity. This state-of-the-art production powder coating line is production ready for large and small volumes.