Full-service thermoplastic and thermoset injection molding for prototype through high-volume production. Deluxe combines scientific molding, in-cavity sensors and robotic tending across 55 presses (20–900 ton) to control cavity pressure, cycle stability and cosmetic finish. Offers multi-shot, overmolding and insert molding to deliver integrated, production-ready parts with tight tolerances and automated handling.

High-pressure injection of molten thermoplastic into precision-machined molds to produce net-shape parts with tight dimensional control and cosmetic finishes. Supports multi-cavity hot-runner tooling, engineered resins, over-molding and automated part handling for medium- to high-volume production.

Plastic Injection Molding

Standard injection molding of melt-processable thermoplastic resins (ABS, PC, PA, PEEK, PP, GF-reinforced compounds) in water-cooled molds. Delivers high-cycle, recyclable parts with tight dimensional control.

Thermoplastic Injection Molding

A plastic injection molding process where preformed components (usually metal) are placed into molds before molten plastic is injected, securely encapsulating the inserts within the finished part.

Insert Molding

Injection Molding (Thermoplastic & Thermoset Production)

End-to-end tooling design, precision mold fabrication and try-out services. In-house CNC, EDM and mold assembly deliver prototype and production-class tools with polishing, hot-runner integration and full validation. Offers mold maintenance, repair and try-out runs to accelerate qualification and stabilize part geometry before production release.

Custom Injection Mold Building delivers end-to-end mold fabrication services, including design translation, precision CNC machining of mold blocks, EDM detailing for fine features, heat-treatment, and assembly of steel, aluminum, and beryllium copper molds for thermoplastic injection molding.

Custom Injection Mold Building

Precision machining, EDM and surface finishing of steel or aluminum molds and transfer pots for rubber molding applications, delivered fully spotted, vacuum-tested and ready for press qualification.

Mold Fabrication (Tool & Die)

Mold Try-Out & Validation involves test runs of new molds on injection presses to verify part quality, cycle times, and dimensional accuracy before full production.

Mold Try-Out & Validation

Tooling Design & Mold Building

Design-for-manufacturability, CAE and rapid prototyping services focused on plastic parts. Offers 2D/3D CAD, mold-flow analysis, prototype 3D printing, CNC prototyping and concept models to reduce cost and cycle time, enabling faster validation and production-ready design transfer.

Plastic Fabrication covers the end-to-end transformation of stock engineering plastics—sheet, rod, tube, or plate—into finished components or assemblies. Core steps include precision cutting, CNC machining, heat or line bending, thermo-forming, solvent/hot-gas/ultrasonic welding, mechanical fastening, and polishing or coating. The integrated workflow enables everything from optically clear display enclosures to high-strength structural parts for aerospace, medical, and semiconductor equipment, delivered with full material traceability and QA documentation.

Plastic Fabrication

3- or 5-axis routing of polyurethane/epoxy tooling board to create prototype molds, drape-form fixtures and styling models with short lead-times and low cost compared to aluminum.

CNC Router Tooling-Board Fabrication

Expedited pad-print trial service producing colour-matched samples within 24 hours, enabling cosmetic approval before production tooling release.

Rapid Pad-Printing Prototype Sampling (24 h)

Part Design, Prototyping & DFM Support

Comprehensive inspection and quality-control services including incoming, in-process and final inspection. IQC leverages CMMs, laser/structured-light scanning, automated vision, SPC, FAI/PPAP reporting and a traceable calibration program (ISO 9001) to deliver data-rich inspection packs and functional test results to customer or industry standards.

Inspection & Quality Control (IQC) comprises the metrology, verification, and documentation activities that ensure parts conform to drawing/CAD requirements, customer specifications, and regulatory standards. IQC spans incoming, in-process, and final inspection and leverages coordinate metrology (CMMs and portable arms), laser/structured-light scanning, optical comparators and vision systems, surface-form metrology (profilometers, roundness/contour testers), nondestructive testing (NDT), and statistical process control (SPC). Results are captured in traceable reports (e.g., AS9102 FAIR, PPAP) tied to calibrated gauges and controlled environmental conditions.

Inspection & Quality Control

Dimensional Inspection verifies that a part’s physical dimensions match design tolerances. Tools include calipers, micrometers, and CMMs, ensuring geometric accuracy of length, width, height, angles, and more.

Dimensional Inspection

Non-contact laser or structured-light scanning capturing point clouds to ±25 µm for CAD comparison, reverse-engineering and dimensional reports.

3D Laser Scanning Inspection

Performs final dimensional gauging, threaded-fastener torque audits, and functional fit/actuation tests on sub-assemblies to ensure compliance with drawing tolerances and customer-specified performance criteria before kitting or shipment.

Dimensional, Torque & Functional QC

In-house secondary operations and value-added finishing to deliver market-ready components. Services include manual and robotic assembly, pad printing, hot stamping, sonic/ultrasonic and spin welding, labeling, custom packaging, kitting and inventory management—minimizing supply-chain handoffs and shortening lead times.

Secondary operations & value-added services encompass in-line or post-process tasks—deburring, tapping, assembly, labeling, special cleaning or final customization—that manufacturers perform in-house but typically do not sell as stand-alone services. This catch-all pillar groups low-visibility steps so buyers understand a supplier’s complete in-house capabilities without cluttering the primary taxonomy.

Secondary Operations & Value-Added Services

Pad Printing is an indirect gravure printing process that transfers a very thin ink film from an etched cliché to a substrate via a compliant silicone pad. Because the pad can deform around complex 3-D geometries, the method excels at applying fine, multicolour graphics, legends, and functional markings to irregular or curved surfaces across metals, plastics, glass, and ceramics.

Pad Printing

Ultrasonic Welding applies high-frequency acoustic vibrations under pressure to form solid-state bonds, often used in electronics and plastics.

Ultrasonic Welding

Assembly & Integration Services encompasses mechanical fastening, ultrasonic welding, heat staking, electronics and hardware integration, sub-assembly kitting, and packaging services to deliver complete assemblies or kits ready for immediate installation or shipment.

Assembly & Integration Services

Precision CNC machining and prototype machining to support mold fabrication and part finishing. Multi-axis milling, turning and mill-turn operations enable tight-tolerance features, fixture work and production-ready machined inserts or secondary-machined parts. Integrated CAM and in-process probing support repeatable quality for low-to-medium volumes.

CNC Machining is subtractive manufacturing performed on computer-numerically controlled machine tools. Toolpaths generated from CAM drive multi-axis milling, turning, and mill-turn equipment to remove material accurately and repeatably. The approach enables tight tolerances, stable process capability, and scalable automation for prototypes through production across metals and engineering plastics.

CNC Machining

CNC Milling removes material with rotating cutters under precise multi-axis computer control, producing complex prismatic or sculpted parts with positional accuracy to ±0.005 mm and surface finishes ≤ Ra 0.4 µm. Machines span 3-axis vertical mills, 4-axis horizontals with pallet changers, and full 5-axis trunnion or gantry platforms, supporting everything from rapid prototypes to lights-out production in metals, plastics, and composites.

CNC Milling

CNC Turning uses computer-controlled lathes to rotate bar, billet, or cast blanks while single-point cutting tools remove material. The process excels at producing concentric OD/ID features, tapers, threads, grooves, and complex contours with tight positional accuracy. Modern CNC lathes support live tooling, Y-axis interpolation, sub-spindle part transfer, and bar-feed automation—enabling complete, high-volume production of precision cylindrical components in metals or plastics.

CNC Turning

CNC Machining & Prototype Machining

A global standard for quality management systems focusing on continuous improvement and customer satisfaction.

ISO 9001:2015

Evidence that an organization follows the AIAG Production Part Approval Process, ensuring that new or revised automotive parts and their associated production processes meet all customer engineering design and specification requirements before volume production begins.

Production Part Approval Process (PPAP) Compliance

The design, fabrication, and assembly of diverse products across multiple end‐use industries or specialized, project‐based needs. Emphasis is on versatility, custom solutions, and broad expertise to handle unique or varied manufacturing projects outside of more narrowly defined sectors.

General Manufacturing

Deluxe Plastics manufactures precision injection-molded industrial components and assemblies and uses in-house machining, robotic automation, and manual assembly to produce custom housings, brackets, and functional parts for general manufacturing applications where turnkey fabrication and end-of-line assembly are required.

High-volume manufacturing of household appliances, personal care devices, and durable consumer products. UL / CE safety, energy-efficiency targets, and cost-optimized injection molding and assembly lines meet global retail quality expectations.

Consumer Goods & Appliances

Deluxe Plastics produces consumer goods and appliance-grade injection-molded components—including decorated dispenser bodies, control-bezel assemblies, and fitted plastic housings—using 2-shot molding, in-mold decorating, precision machining, and automated assembly for finished retail appliances and consumer products.

The design, manufacturing, and assembly of components and systems for passenger cars, commercial and off-highway vehicles, rail rolling stock, and emerging electric/Autonomous mobility platforms. High-volume production, IATF 16949 compliance, JIT supply chains, and continuous innovation ensure reliable powertrains, safety-critical systems, and cost-efficient delivery across a broad transportation landscape.

Automotive & Transportation

Deluxe Plastics supplies precision-molded automotive and transportation components such as interior trim, instrument bezels, and insert-molded assemblies, leveraging automation (Star robots), precision machining, and in-house assembly to meet tight tolerances and high-volume production requirements.

The development, manufacturing, and supply of precision-engineered medical systems, devices, and critical components, including diagnostic equipment, surgical instruments, implantable devices, laboratory systems, and precision medical components. Emphasizes adherence to ISO 13485 and FDA QSR standards, traceability requirements, sterile processing, rigorous validation, and use of biocompatible materials such as titanium, stainless steel, and medical-grade polymers to ensure patient safety and clinical effectiveness across global healthcare settings.

Medical Devices & Healthcare Equipment

Deluxe Plastics manufactures medical-grade molded devices and components—sterilizable plastic housings, diagnostic disposables, and precision over-molded subassemblies—using controlled molding processes, precision machining, and validated manual and robotic assembly to support healthcare device applications.

Involves the fabrication and assembly of electronic components, semiconductor devices, printed circuit boards, and advanced microelectronics, as well as the manufacture of supporting mechanical components such as casings, enclosures, and structural parts. Cleanroom processes, ESD controls, precision machining, and adherence to industry standards (e.g., IPC, JEDEC) are critical for achieving high-density, high-performance products in mass-market, specialized, and ancillary applications.

Electronics & Semiconductors

Deluxe Plastics fabricates custom molded electronic components and enclosures—including PCB housings, connectors with insert molding, and decorated control panels—using precision injection molding, machining, automated vision inspection, and both robotic and manual assembly for electronics applications.

Machinery, filling, and packaging solutions for meat, dairy, beverage, and ingredient lines. USDA / FDA sanitary design, corrosion-resistant materials, and high-throughput automation preserve product quality and safety in regulated processing environments.

Food & Beverage Processing

Deluxe Plastics produces sanitary, food-contact plastic components—such as dispensing parts, machine housings, and molded fittings—utilizing engineered resins, precision molding, machining, and assembly operations that comply with food- and beverage processing requirements for hygienic production lines.

Deluxe Plastics is a turnkey plastic injection molding partner offering in-house part design, mold building, tooling maintenance, and end-to-end secondary operations supported by automation and robotics. Operating 55 presses across three Wisconsin facilities and an overseas plant, Deluxe delivers high-volume and complex, tight-tolerance parts, with capabilities including two-shot and overmolding, in-house CNC/EDM toolmaking, vision inspection, PPAP/FAIR, and an ISO 9001:2015 quality management system for regulated industries.

Headquarters and engineering office located in Green Bay. Functions include corporate HQ, Alwin Manufacturing’s Hygiene Division, and local assembly capabilities. The site supports project engineering, product assembly and serves as a regional hub for customer engagement and specialty assembly programs.

Green Bay Headquarters

Clintonville injection molding facility hosts production operations and remains a core manufacturing site for Deluxe Plastics. The location supports mold maintenance, molding runs, and secondary operations and is noted as the company’s original operating location since founding.

Clintonville Manufacturing

Medford is a 100,000 sq. ft. manufacturing and warehouse facility equipped for high-volume, complex and tight-tolerance injection molding. It features overhead cranes across press lines, advanced automation and robotics, and a two-booth robotic paint line to control finishing and production timelines.

Medford Manufacturing

Overseas injection molding facility in Vietnam providing cost-effective production and assemblies to support international and U.S.-bound shipments. The site mirrors domestic quality controls to produce high-quality molded parts at competitive cost points.

Vietnam Injection Molding Facility

Turnkey injection molding and mold-building partner with in-house toolmaking, secondary ops, automation, and ISO 9001:2015 quality systems.

Deluxe

Custom Plastic Injection Molding

Injection Molding (Thermoplastic & Thermoset Production)

Processes & Services

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Locations & Facilities

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