PCS Blog

When it comes to mold building, PTA Plastics takes DIY to the next level—part of its mission to be a disruptor in its market segment.

Founded in 1953 in Bridgeport, Connecticut, the now fully employee-owned company builds 90% of its tooling in-house. PTA produces between 100 and 125 tools per year, with 85% supporting the medical industry.

Most of PTA’s mold building takes place at its Longmont, Colorado facility, with additional support from its team in Oxford, Connecticut. All molds—ranging in size from 12 to 48 inches square—are customized with core cavity inserts that must drop into bases made to exacting standards.

PTA’s low-volume, high-mix production for top medical OEMs results in approximately 250 mold changeovers per month at each facility. PTA also maintains ISO 13485:2016 (medical device QMS), ISO 9001:2015, and MedAccred accreditation.

That adds up to a high bar to meet, says PTA Plastics President Rich Dorans—but PTA has a secret weapon.

To meet the rigorous demands of medical part production, PTA partners with mold base supplier PCS Company—the only U.S.-based company that not only manufactures mold bases, but also supplies mold components and molding products. Their partnership, spanning over five years, is a testament to creating a tightly controlled supply chain built on mutual knowledge sharing and best practices.

The collaboration between PCS and PTA “is unusual today and an advantage over our competition,” Dorans says. “We specialize in mid-volume injection molding, value-added assembly, full engineering support, and in-house tooling. Our upfront engineering and DFM support help us reduce lead times and eliminate many post-Tier 1 issues common to other programs.”

A Versatile Fleet of Machines

PTA specializes in durable products for leading medical OEMs—items like automated external defibrillators and patient monitors.

To produce them, PTA utilizes 41 total injection molding machines. In Colorado, the company operates 20 IMMs ranging from 30 to 1,235 tons, while the Connecticut site runs 20 IMMs from 45 to 720 tons.

These machines are loaded with molds built in-house by PTA and mounted on bases provided by PCS. PCS handles finishing on pockets, ejector holes, water components, and hot-tip geometry.

“We're doing all of the fitting, so it's a big time saver,” Dorans explains. PTA’s 12 toolmakers check the bases for squareness, drop in the core cavity inserts, and complete the fitting. Most molds are produced in eight to 12 weeks. Some incorporate 3D-printed conformal cooling channels provided by third-party vendors. PTA is also adding a Zeiss CT scanner to enhance its validation process.

Among PTA’s CNC machines are Makino, Mori Seiki, 5-axis DMG, and a 5-axis Röders electrode machine. Industry 4.0 capabilities are being integrated across PTA’s molding cells. Three mold designers—part of a 250-person staff across both facilities—use Cimatron CAD/CAM software.

D&M Tool Corporation is a busy mold builder. According to General Manager Brad Cummings, his team is always on the lookout for supplier products and tools that can streamline the mold-building process. One such tool is the mold base configurator from PCS Company. Cummings mentioned that this valuable resource was almost overlooked initially. Located in Springville, Indiana, D&M specializes in manufacturing small to mid-size injection molds. They produce molds ranging from single cavity to 16 cavities, as well as die-cast tooling and machining of components in their 18,000-square-foot facility. The company’s expertise lies in molds for automotive lenses and they also cater to the electronics (lighting for airports, parking lots, retail stores and headlights for cars) and medical device industries. Sister company, PRD, Inc., also based in Springville, offers tight tolerance injection molding services and operates most of the molds built at D&M. Press sizes at both companies range from 20 tons to 610 tons. D&M and PRD, Inc. are divisions of Specialty Manufacturers Inc. Cummings recalls that it was about a year ago when they first heard about the Mold Base Configurator from PCS Sales Representative Mike Hyde.

“I was too busy to even consider it. It seemed easier to stick with our previous mold base supplier, as we were satisfied with their service and pricing,” says Cummings. After persistent encouragement from Hyde, Cummings finally agreed to test out the configurator. “Tim Pruett, our mold designer, was the first to place an order. He had the previous supplier’s mold base data saved on his computer, and we were worried that PCS’s data might not be compatible, which would make it difficult to set up everything the way we needed,” he explains. When the mold base arrived, Cummings asked his team to carefully inspect every aspect of the order and inform him if they noticed anything that was out of specification or missing. He was relieved to find that their concerns were unfounded. According to Cummings, everything was perfect and matched the 3D models exactly as Pruett had specified on the prints.

Streamlined Efficiency in Mold Base Ordering

The company has placed orders for several mold bases in the past few months and has also provided quotes for many more. Cummings is consistently impressed by the speed and ease of use of PCS’s mold base configurator. The efficiency of the configurator has had a significant impact on D&M’s project timelines, enabling them to order mold bases more quickly and receive them faster. “This accelerates our project timelines and enhances customer satisfaction, “says Cummings. The development of this enhanced system by PCS wasn’t by chance. “We already had a configurator in place, but we knew we needed to do more. We studied the limitations carefully to understand how to expand the product line and enhance the customer experience. This led us to adopt new technology and create a new generation of standard mold base configurators,” says Joe Esposito, PCS engineering manager. The system dynamically offers compatible components based on the customer’s mold base configuration, ensuring all components within the assembly, including quantities and part numbers, are correct. This smart selection technology has eliminated previous issues with incorrect selections and typos that often led to product returns and delays. “I simply log in and use the dropdown menus within the order form to choose the type of mold base I want, along with the machining features and components needed. One great advantage is that the configurator calculates the price as I go line by line, selecting or removing any aspect of the order, so I know in real-time exactly what everything costs. If I quote a job for a customer and later, we get the P.O., I can go back into the configurator and order the mold base without having to reenter anything. The entire process takes me about a minute, and boom, it’s done. I get a confirmation email immediately with delivery details, and each order has arrived correct and on time, usually in just three to four days,” says Cummings.

Cost-Effective Solutions and Enhanced Support

Cummings and Pruett expressed their appreciation for the level of customer service provided by PCS. For example, the first time D&M used the configurator, they could not find the locating ring to fit the company’s standard. Pruett called PCS’s Hyde, and he promptly resolved the issue. This kind of responsive support is no accident – PCS maintains a robust feedback system, with their sales and estimating teams regularly collecting customer input to drive improvements. The engineering team targets annual enhancement updates based on this feedback, along with planned product improvements. “One of our primary goals was to clear all the bottlenecks we identified in the previous version. The improvements in speed, accuracy and ease of use have helped us retain and expand our customer base significantly,” says Esposito. The integrated interface generates CAD models, BOMs and quote documents dynamically, enabling thorough verification before placing orders.

Customers can instantly get quotes and delivery times for multiple configurations, helping them make better decisions. This self-service approach means users can work on their projects regardless of the time of day or day of the week, without requiring human interaction. Cummings mentioned that the pricing is more affordable than with previous suppliers, with every mold base ordered offering noticeable savings. Because PCS has removed the cost associated with quoting these mold bases, they have been able to pass along these savings to the customer. Additionally, the products are more readily available and often shipped and delivered more quickly. Cummings and Pruett mention another added benefit of working with the 3D model in the mold base configurator. They explain that the chamfers on the corners are not displayed, which makes it much easier to create the drawings. They also note that when the mold base is delivered, the chamfers are there as designed. The adoption of the configurator has opened up new opportunities for D&M. It enables them to take on more jobs by responding to quotes more quickly and accurately. Cummings says, “We’ve obtained more jobs by meeting our deadlines faster.” This efficiency has helped them reduce stock levels because they only order what is needed when they need it, improving their inventory management and cash flow. D&M Tool is currently using PCS’s standard mold base configurator, which provides frame options ranging from 7.875 inches × 7.875 inches to 23.75 inches × 35.5 inches. The A and B plate thicknesses offered range from 0.875 inches to 5.875 inches, all available in either #3 or #7 steel. PCS also offers its F.I.T.S. (Fast Interchangeable Tooling System) Insert configurator, compatible with MUD and RTI frames, which D&M intends to use for future jobs as needed. “The mold base configurator has greatly improved our ordering and quoting process. It is now our primary source for mold bases, along with PCS’s pins, parting line locks, lifters and other products that we use for every mold we build,” says Cummings.

Unlock Greater Efficiency and Flexibility with PCS Company’s Expanded F.I.T.S. Product Line

In today’s competitive manufacturing landscape, adaptability and speed are critical to success. PCS Company’s F.I.T.S. is revolutionizing how manufacturers approach mold building and injection molding. By combining a reusable frame with interchangeable inserts, F.I.T.S. empowers molders, mold makers, and OEMs to optimize processes, save costs, and enhance production capabilities.

Now, with the introduction of new sizes and expanded product options, PCS is taking F.I.T.S. to the next level, offering even more versatility to meet diverse customer needs.

What is F.I.T.S.?

F.I.T.S., or Fast, Interchangeable Tooling Systems, is a modular tooling solution that separates the mold into two key components:

The Reusable Frame: A durable, one-time investment designed to support various projects.

The Insert Assembly: Customizable tooling components that are easily swapped out to accommodate different parts or product families.

This innovative system excels in flexibility, enabling rapid mold changes, quicker prototyping, and reduced tooling costs.

Why Choose F.I.T.S.?

The modular nature of F.I.T.S. delivers unparalleled benefits across the production chain.

For mold makers it offers reduced lead times, thanks to fewer plates and machining details, plus simplified and streamlined manufacturing processes.

For mold operators mold changes are completed in minutes, enhancing operational agility. In addition to significant storage space savings compared to traditional molds; operators receive lower unit costs for molded products, as only the inserts are replaced for each new product.

For OEMs F.I.T.S. offers accelerated time-to-market for new products and lower initial tooling costs, making prototyping and experimentation more affordable. With F.I.T.S. OEMs also gain the flexibility to test multiple product variations or adjust designs based on market feedback.

Expanded FITS Product Line: Meeting Customer Demands

To better serve the needs of the manufacturing community, we have expanded our F.I.T.S. lineup, introducing new sizes and configurations that enhance the product line’s functionality.

New T-Style Insert Assemblies and Replacement Plates: Coming soon for the 10/12 and 10/14 series, providing greater flexibility for a wide range of projects.

In addition to these new insert assemblies and replacement plates we offer new A-Plate and B-Plate thickness options: Laminated inserts for the 10/12 and 10/14 series will include more options, ensuring optimal compatibility for unique applications.

Sleeve Ejector Plate Sets: Added for the 08/10, 84/90, 10/12, and 10/14 series, giving molders even more choices.

These enhancements stem from our commitment to listening to customer feedback and adapting to market demands. According to Derrick Jones, Vice President of Sales and Marketing, “This product line expansion is happening because we are listening to the voice of customers. Our F.I.T.S. system stands out for its comprehensive features and quality support.”

Comprehensive Features and Customization

We strive to set PCS Company apart by offering a complete, ready-to-use F.I.T.S. system with features designed to maximize efficiency.

Dual-Function Stripper Bolts: Serve as stoppers and guides, preventing damage and ensuring safe, reliable performance.

Leader Pins: Larger inserts include four leader pins for enhanced stability, while the plus series of smaller inserts also feature this design to protect delicate cores and intricate shut-offs.

Mini Hot Sprue Bushings : Seamlessly integrate into F.I.T.S. assemblies for runner-less or semi-runner-less as well as cosmetic and special gating needs providing efficient material flow.

Pry Slots: Simplify handling and quick insert changes, included in every A-Plate for ease of handling.

Customizable Solutions: Send your CAD file to PCS for custom machining tailored to your specific needs.

For convenience, the PCS Configurator tool allows you to quickly select, price, and order F.I.T.S. inserts online. Instant pricing ensures informed purchase decisions, saving time and effort.