WJ Die Mold has specialized in plastic injection molding and insert molding manufacturing since 1982. Whether you require a custom molded or special inserted part, we have the experience in a wide variety of thermoplastics and engineering materials to deliver exactly what you need, when you need it.

Our sophisticated equipment allows us to minimize set-up time and in-process adjustments , maximize output and run at optimum capacity. Combined with little overhead, we can offer you some the most competitve pricing in the industry.

Our Quality Control System is based on ISO9001:2008 standards. Every job has a control plan to identify critical production criteria. Each control plan is carefully monitored throughout the manufacturing process. We utilize 100% in-process inspection as well as first piece qualifcations and batch capability studies to ensure a flawless delivered product.

WJ Die Mold’s mission is to prduce high quality molds and products, in the most cost effective manner for your complete satisfaction. Our 30 year reputation is riding on it!

Our History

In 1982, Wayne Johnson and Jim Goddyn formed a partnership to produce plastic injection and die cast molds for the manufacturing industry.

They rented a 500 sq. ft. space in Schaumburg, Illinois.

Over the next few years expansion continued and equipment was added, including more Bridgeport Mills, Grinders and EDM Machining Centers.

In 1987 W. J. purchased (2) 50 ton plastic molding press to produce 1st article samples and provide production to customers.

In April 1993, a 1,800 sq. ft. building was purchased in Schaumburg.  Expansion continued and equipment was added, including Wire EDM Machining Center and (1) Vertical Insert Molding Machine.  As the production increased in the molding area, W. J. purchased (5) more injection molding presses from 50 to 120 tons.

By 1997, W. J. Die Mold had outgrown it’s facilities several times and tripled in size to a new 6,000 sq. ft. building.

A Coordinate Measuring Machine was purchased for new inspection department.  W.J. opened a piece part inspection department to handle the increased demand for molded parts to be inspected before tool shipment.  And, an increased size in molding led to purchase another 120 ton Van Dorn molding press.

In May 2008, W. J. Die Mold was certified and registered with ISO 9001 with the ISO9001:2000 Quality Assurance Standard. In June of 2010 we updated to ISO2001:2008.

W.J. has the capabilities using the latest technology and equipment to service over a dozen industries.  We welcome your business. Email Jim your next project specs and we’ll contact you immediately.

WJ Die Mold Standard Services:

Injection Mold Sampling
Plastic Injection Mold Production
Insert Molding
Trimming and Assembly
First Piece Qualification
In-Process Inspection
PPAP Reports
ISO9001:2008 Standards

WJ Die Mold uses the following equipment to minimize set-up time and in-process adjustments, maximize output and run at optimum capacity. Combined with little overhead, we can offer you some the most competitive pricing for tooling, die cast molds and injection molding, in the industry.

Tooling Machine Centers

• Bridgeport Mills with Readout System
• Hand Surface Grinder with Readout System
• Automatic Surface Grinder
• Drill Press
• Band Saw
• Cutter Grinder
• Electronic Discharging Machining Centers

Plastic Injection Molding Presses and Tie Bar Information

• 200 Ton (JSN), 20 x 20
• 120 Ton (Van Dorn), 17 x 17
• 85 Ton (Van Dorn), 13 1/2 x 16
• 80 Ton (Cincinnati), 14 x 16
• 50 Ton (Newbury), 10 1/2 x 10 1/2
• 80 Ton Rotary Press (Newbury), Vertical

Auxiliary Equipment

• Robotic Sprue Pickers
• Automatic Conveyor Separators
• Hot Oil Thermolator
• Automatic Colorant Feeder
• Automatic Material Proportion Loaders
• 4 Stage Water Chiller
• Temerature Control System

Software

• Solidworks 2011
• Fastsurf with Fastsolids Modules in Cadkey

Put our technology to work for you. Email Jim your next project specs and we’ll contact you immediately.

WJ Die Mold Standard Services:

Injection Mold Sampling
Plastic Injection Mold Production
Insert Molding
Trimming and Assembly
First Piece Qualification
In-Process Inspection
PPAP Reports
ISO9001:2008 Standards

WJ Die Mold offers Insert Molding Services as an add-on to the plastic injection molding process.  There is one direct difference between the two processes; the plastic injection molding process only uses plastic material in order to create a product.  On the other hand, the Insert Molding process includes other types of plastic and/or metals in order to create a more advanced product. There are thousands of uses for Insert Molding manufacturing.

The Insert Molding Process

The Insert Molding process starts off by either inserting the metal inserts before the custom injection molding process, or they can be inserted during the custom injection molding process.  If the inserts are chosen to be inserted during the plastic injection molding process, an Insert Molding process operator or a robotic arm will load them.  If chosen to insert the metal inserts after the plastic injection molding operation, the same robotic arm or Insert Molding process operator will load them after the plastic injection molding process is complete. Usually, Insert Molding takes place after the custom injection molding process. This procedure ideally reduces insertion costs, which can save our customers substantial costs on custom insert molding projects.

Regarding the Insert Molding process, there can be some very nice advantages when a robotic arm is handling parts.  When it comes to removing the molded parts and getting them ready for more processes, a multiple-axis robot can do that faster and more accurate than a human.  After the molded part is created and removed from the mold, the robot grips the part and moves it to either a location to be held or onto a system to be inspected.  The manufacturing equipment’s general layout and the kind of product being created are the determining factors in making this choice.

In order to assure a high level of quality for many parts that go through Insert Molding, robots can have vision systems mounted on them.  These vision systems inspect parts faster than a human, as well as know exactly what the metal component’s placement accuracy is.

Several industries thrive upon the products created through the Insert Molding process.  Actually, there are so many products created through this type of custom injection molding.  Here is a list of the industries these products belong to, and there is a list of the products that are created through this type of custom injection molding:

Automotive and Industrial Uses for Insert Molding

• Cable Assemblies
• Sensor housing
• Seat adjustment motor’s brush holder
• Motor end bell
• Sound system’s speaker coil (also used for the electrical industry)
• Gear housing
• Motor assembly’s window lift actuator
• Interior lighting base
• Components for alternator
• Module parts for engine control

Healthcare Industry Uses for Insert Molding

• Delivery storage units for DNA testing
• Surgical blades
• Dental instruments
• Motors, gears and precision parts dental, medical, and surgical devices

Other Industries

• Surge protectors
• Buck knives
• Yo-yos
• Kitchen knives, forks, and spoons
• Humidity sensor clips
• Faucet handles…and so much more.

WJ Die Mold has the experience and expertise for just about any custom injection molding or insert molding project. Let us take a look at your specs and quote you a price. Email Jim and we’ll contact you immediately.

WJ Die Mold Standard Services:

Injection Mold Sampling
Plastic Injection Mold Production
Insert Molding
Trimming and Assembly
First Piece Qualification
In-Process Inspection
PPAP Reports
ISO9001:2008 Standards

Many industries rely on Plastic Injection Molding to create most of today’s products and/or parts of products which are sold on the market.

The Plastic Injection Molding process

The process starts by having grains of plastic fed into a heated barrel from a hopper. Actually, the granular plastic is forced into the heated barrel by gravity. When the plastic granules make their way into the heated barrel, a screw-type plunger slowly moves them forward into a heated chamber. The chamber melts the plastic. As the same plunger advances, it forces the melted plastic through a nozzle. This nozzle rests against the mold. The melted plastic then enters through a runner and gate system to fill the mold cavity. After entering the mold cavity, the plastic solidifies. The plastic usually solidifies just as soon as the whole entire mold is filled, because the mold remains cold throughout the whole Plastic Injection Molding process.

There is a sequence of events during the Plastic Injection Molding called the injection molding cycle. First, the mold closes. After it closes, a polymer is injected into the mold cavity. Material shrinkage is compensated. This compensation is maintained by a holding pressure after the mold cavity is filled. After this action, a screw turns. After this screw turns, the next shot is fed to the first screw. The next shot is prepared once the screw retracts. After it opens, the part is ejected.

In order for the custom injection molding process to take place, the mold must be lubricated and cooled. Water is mostly used as the mold’s cooling agent. Quick cooling times are accounted by channeling water through to the mold. When it comes to Plastic Injection Molding, faster cycle times are allowed by making sure the mold is very cold. The custom injection molding industry depends on the mold to be colder. This allows a Plastic Injection Molding manufacturer to produce more parts.

In Plastic Injection Molding, there is a molding tolerance. A specified allowance in parameters on the deviation is the molding tolerance. These parameters are angles, dimensions, shapes, or weights. There is a maximum and minimum limit on thickness. This helps you set tolerances. Setting a molding tolerance is highly needed in the Plastic Injection Molding process. ±0.008 to ±0.002 inches is the possible tolerance of a thermoset or a thermoplastic.

Materials Used in Plastic Injection Molding and Insert Molding Processes:

• Polystyrene
• Polyethylene
• Nylon
• Phenolic
• Epoxy

Troubleshooting the Plastic Injection Molding Process; Four main troubleshooting phases

• Metering Phase
• Injection Speed
• Sink mark/Gate freeze or Gate seal/Geometry and Weight Studies
• Cooling Time

There can be some possible defects during the Plastic Injection Molding process. These defects are usually caused when the cooling rate is not in unison:
• Flash
• Warping
• Unfilled Sections
• Bubbles
• Sink Marks
• Ejector Marks

During the Plastic Injection Molding process, these defects can be prevented. WJ Die Mold adheres to all quality procedures in the ISO 9001:2008 specification assuring you of a perfect job every time. We welcome the opportunity to show you what we can do.

Email Jim with your specs and we will contact you immediately.

WJ Die Mold Standard Services:

Injection Mold Sampling
Plastic Injection Mold Production
Insert Molding
Trimming and Assembly
First Piece Qualification
In-Process Inspection
PPAP Reports
ISO9001:2008 Standards

The tool room prides itself in precision mold making of the highest quality. Our tooling services address a wide range of customer requirements from single cavity prototype molds to multiple cavity high volume production molds.

WJ Die Mold Standard Services:

Injection Mold Sampling
Plastic Injection Mold Production
Insert Molding
Trimming and Assembly
First Piece Qualification
In-Process Inspection
PPAP Reports
ISO9001:2008 Standards

WJ Die Mold offers you a complete one stop shop for custom mold, tooling and product design services so you receive a completed part that is functional, reliable, manufacturable, economical and aesthetically pleasing.

We understand the benefits of detailed cost and ROI implications of a particular design and can provide you with the quantitative measures you need to make a well informed decision. Our vast experience with mold flow design will save you on production costs because we know where issues may arise in the design of molds. We can help with all aspects of mold design engineering including wall thickness, runners, corners, angles, ribs and much more.

Basic information required for a plastic injection molding design project:
Do you have a part drawing or sample?
How many parts to be molded over the life of the mold?
Must the product fit with other parts and what are the tolerances?
What is the molding characteristic of the specified plastic?
What is the shrinkage?
What are the draft angles?
What is the finish?
Do you need an engraving on the part?
Timing of the project?

Contact us today, we can help with your next project.

WJ Die Mold Standard Services:

Injection Mold Sampling
Plastic Injection Mold Production
Insert Molding
Trimming and Assembly
First Piece Qualification
In-Process Inspection
PPAP Reports
ISO9001:2008 Standards