Echo Molding operates a fully automated, ISO-9001 facility with twenty-nine servo-hybrid Nissei presses from 70- to 950-ton clamp force and up to 168-oz shot size. Scientific molding, mold-flow-optimized tooling, and real-time SPC deliver ±0.002 in repeatability. Robotic extraction, centralized resin handling, and quick-change tooling keep cycle times low, scaling efficiently from 50 to 50,000,000 parts.

Assorted injection-molded parts—fan blades, housings, brackets, trays

Color-matched ABS covers with textured, vented surfaces

Precision molded parts—enclosures, caps, inserts, tooling samples

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

A plastic molding process where an initial molded part or substrate is further encapsulated with another plastic layer, enhancing durability, ergonomics, or aesthetics.

Overmolding

Scientific/Precision Molding utilizes in-mold sensors and closed-loop SPC monitoring to maintain tight process control and ensure consistent part quality.

Scientific/Precision Molding

Injects high-pressure nitrogen (7 – 35 MPa) into a partially filled thermoplastic cavity to hollow out thick sections, reducing sink marks, cycle time, and part weight while maintaining surface quality.

Gas-Assisted Injection Molding

A low-pressure injection molding process in which a thermoplastic melt is combined with a blowing agent (chemical or physical) to create a cellular core with solid outer skins. The foamed core reduces density and internal stresses, enabling thick-wall, large-format parts with minimal sink and warpage at lower clamp forces than conventional injection molding. Commonly used for enclosures, panels, pallets, machine bases, and structural housings where stiffness-to-weight and dimensional stability are critical.

Structural Foam Molding

Advanced Plastic Injection Molding

Echo Molding’s heritage as a toolmaker underpins its ability to design, build, and maintain high-precision aluminum and steel injection molds in-house. Using 4- and 5-axis CNC machining centers (travels up to 60 × 80 in) and both sinker and wire EDM, the team produces prototype and high-volume tools—including multi-cavity hot-runner molds, complex slide/unscrewing mechanisms, and BeCu inserts for rapid cooling. On-site mold try-outs validate fit and function on presses up to 950 ton before full production.

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

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

Sinker (RAM) Electrical-Discharge Machining plunges a custom-shaped graphite or copper electrode into a dielectric-oil gap, eroding hardened tool steels, carbide and super-alloys by controlled spark discharge. The process delivers blind cavities, sharp internal corners and deep ribs that are impossible to mill, with ±0.0002 in accuracy and Ra ≤ 8 µin surfaces after multi-skim finishing passes.

Sinker EDM

Wire Electrical-Discharge Machining (EDM) drives a continuously spooled brass or coated-copper wire—Ø 0.004 – 0.012 in—through a de-ionized-water work tank while pulsing 60–300 V discharges between the wire and a grounded, fully conductive workpiece. Material is removed electro-thermally, leaving no cutting forces, enabling burr-free slots, internal corners down to 0.002 in radius, and high-aspect-ratio profiles in hardened tool steel, carbide, titanium and super-alloys. Multi-skim finishing passes routinely hold ±0.0001 in dimensional accuracy and surface finishes to 4 µin Ra (0.1 µm), while rotary axes and adaptive power control permit complex taper, helical and stack cutting without distortion or recast layer.

Wire EDM

Multi-Cavity & Complex Action Molds encompass the design and fabrication of molds with multiple cavities or integrated mechanical actions such as lifters and collapsible cores.

Multi-Cavity & Complex Action Molds

Tooling Maintenance & Refurbishment encompasses scheduled preventive maintenance and corrective refurbishment of dies, molds, and tooling used in forming or molding operations. This service extends tool life, ensures dimensional accuracy, and maintains surface finish quality. Activities include surface re-polishing, core replacement, dimensional re-machining, and structural repair to restore the tool to original specifications or better.

Tooling Maintenance & Refurbishment

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

Precision Mold Design & Mold Making

Echo Molding delivers turnkey, in-house post-process decoration and finishing—including pad and screen printing, hot-stamped foils, precision polishing, and tool-room machining. Integrated with molding cells, these services produce ready-for-market parts with durable graphics and cosmetic surfaces while maintaining tight dimensional control. (No in-house spray painting or EMI/RFI shielding.)

Surface treatment & finishing encompasses chemical, mechanical and thermal operations—tumbling, vibratory deburr, abrasive blasting, electropolishing, anodizing, chromate conversion, hard-chrome or nickel plating, powder coating, wet painting and ceramic or PVD/CVD overlays—that modify a part’s surface for appearance, corrosion resistance, wear protection or adhesion. Processes routinely achieve ≤ 8 µin Ra finishes, controlled coating thickness from 0.0001 in to 0.010 in and salt-spray performance exceeding 1 000 h to ASTM B117.

Surface Treatment & Finishing

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

Screen Printing forces ink through a patterned mesh stencil onto flat or slightly curved substrates, building opaque graphics, legends, and functional layers with tight registration across plastics, metals, glass, and films.

Screen Printing (Silk-Screen Printing)

Hot Stamping & Foil Decoration applies metallic and pigmented foils to plastic parts using heat and pressure for decorative and functional finishes.

Hot Stamping & Foil Decoration

Polishing / Grinding encompasses abrasive stock-removal and surface-refinement operations applied after rough machining or heat treat. Grinding with bonded-abrasive wheels (Al₂O₃, SiC, CBN, diamond) brings parts to final size, geometry, and flatness, routinely holding ±0.002 mm and roundness < 0.001 mm on hardened steels > 60 HRC. Subsequent polishing stages—belt, buff, super-finishing, micro-finishing, or lapping—reduce surface roughness to Ra 0.05 µm–0.20 µm, produce plateau finishes for bearing surfaces, or achieve mirror cosmetics before coating or plating. Coolant-flooded machines, automatic size-control gauging, and filtered oil or water emulsions ensure thermal stability and contamination-free finishes for aerospace, medical, mould-and-die, and precision fluid-power components.

Polishing / Grinding

Manual Machining & One-Off Tool-Room Jobs involve conventional machining using manual lathes, mills, and surface grinders for low-volume, prototype, maintenance, or fixture fabrication tasks. This operation is ideal where CNC programming and setup time would be inefficient. It relies on skilled machinists capable of executing tight-tolerance work through hands-on precision methods, including hand-scraping and manual fitting.

Manual Machining & One-Off Tool-Room Jobs

Secondary Operations & Surface Finishing

Echo Molding offers turnkey mechanical, ultrasonic, and thermal assembly supported by torque-controlled tooling, custom fixtures, and in-line QC. Integrated kitting, barcoded labeling, and drop-shipping let customers receive retail-ready or line-side kits direct from the molding floor, reducing supply-chain touches and inventory.

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

Mechanical Assembly delivers torque-verified installation of fasteners, snap-fits, and press-fits to build robust sub-assemblies.

Mechanical Assembly

Ultrasonic Welding & Heat Staking joins plastic components using high-frequency vibrations or thermal staking for strong, precise bonds.

Ultrasonic Welding & Heat Staking

Hardware & Electronics Integration assembles PCBs, cable harnesses, sensors, and connectors into plastic enclosures for functional assemblies.

Hardware & Electronics Integration

Packaging / Kitting is a value-added service involving the sorting, assembly, and packaging of individual components into organized kits or finished sets. This service streamlines downstream operations such as final assembly, inventory management, and logistics by ensuring that all required items are grouped, labeled, and packed for efficient delivery and use. Typical use cases include service kits, BOM-based assembly packs, and retail-ready bundles.

Packaging / Kitting

Packaging, kitting & logistics services provide end-to-end fulfillment solutions including component kitting, custom packaging, bar-code labeling and distribution. Facilities integrate WMS/ERP, 3PL interfaces and 2-D-barcode traceability to streamline order accuracy and reduce inventory overhead.

Packaging, Kitting & Logistics Services

Drop-Shipping provides vendor-managed inventory and direct shipment of finished goods to end customers, eliminating intermediate handling.

Drop-Shipping

Assembly & Packaging Services

Echo Molding’s engineering group turns concepts into production-ready parts through iterative CAD design, mold-flow-guided DFM, and rapid aluminum tooling. Using leading CAD/CAM suites, they import native files, optimize wall thickness, runner placement, and cooling, then deliver functional prototypes—often in days—that mirror final production quality. Environmental and functional validation ensure each design is robust before steel is cut.

End-to-end engineering and design services including CAD/CAE modeling, finite-element analysis, tolerance stack-up, DFM/DFA feedback and fixture design. Teams leverage multi-CAD platforms and PLM integration to deliver manufacturable product designs optimized for cost, performance and assembly.

Engineering & Design Services

Design-for-manufacturability and design-for-assembly consulting evaluates product designs for optimal manufacturability, assembly cost reduction and quality control. Experts deliver actionable reports on feature simplification, material selection, draft angles and assembly gauge strategies to reduce cycle times and scrap rates.

DFM / DFA Consulting

Imports and validates customer CAD data from STEP, IGES, Parasolid, ACIS, and native formats (SolidWorks, CATIA, NX, Creo). Geometry is checked for corrupt faces, missing features, and unit mismatches before downstream CAM or documentation.

CAD Model Import & Translation

Mold Flow Analysis uses computational fluid dynamics (CFD) simulations to predict plastic melt behavior, optimize gate locations, and identify potential defects before tooling fabrication.

Mold Flow Analysis

Rapid, multidisciplinary build of functional prototypes that bridge industrial design and engineering validation. Combines additive manufacturing, CNC machining, soft tooling, electronics integration, and functional testing in tight sprint cycles to prove form-fit-function and gather user feedback before production tooling.

Prototype Development (Concept-to-Function)

End-of-line electrical, pneumatic or hydraulic functional verification with data-logged calibration traceable to ISO 17025 or MIL-STD standards.

Functional Testing & Calibration

Design & Prototyping Services

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

ISO 9001:2015

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

Echo Molding, Inc. provides precision injection-molded plastic components and assemblies for the automotive industry, supporting applications in passenger and commercial vehicles with high-volume production and quality standards.

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

Echo Molding, Inc. manufactures precision molded parts and assemblies for medical devices, delivering components that meet stringent quality and regulatory requirements for healthcare applications.

Focuses on equipment and components for data transmission and communication networks, including routers, switches, antennas, and fiber optic cables. Requires strict precision, high-volume output, and compliance with global connectivity standards (e.g., IEEE, 3GPP).

Telecommunications

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

Echo Molding, Inc. produces injection-molded plastic components and assemblies for telecommunications equipment, ensuring precision and compliance for network hardware such as routers and antennas.

The design, manufacturing, and integration of high‐precision components, systems, and subsystems for commercial aircraft and military platforms, with emphasis on meeting stringent certifications such as AS9100, ITAR, and MIL‐STD. Priorities include advanced materials, rigorous quality assurance, and robust engineering to ensure reliability in mission‐critical applications.

Aerospace & Defense

Echo Molding, Inc. delivers high-precision molded parts and assemblies for aerospace and defense applications, including commercial and military aviation components requiring stringent quality and certification standards.

Structural steel, prefabricated assemblies, HVAC modules, and envelope systems supplied to residential, commercial, and infrastructure projects. ASTM / ICC code compliance and BIM-ready data enable efficient, high-quality building delivery.

Construction Products & Building Materials

Echo Molding, Inc. supplies custom injection-molded components and assemblies for building and construction applications, supporting structural and architectural product manufacturing with precision and volume flexibility.

Focuses on fabricating structural systems, specialized flooring, and load-bearing frames for commercial fitness facilities, aligning with health and safety codes.

Gym & Fitness Centers

Echo Molding, Inc. fabricates durable plastic housings, grips, and frame components for commercial fitness equipment, ensuring ergonomic and impact-resistant parts for gym 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

Echo Molding, Inc. manufactures injection-molded components and assemblies for food-service equipment, ensuring sanitary and durable parts for commercial food-processing and service applications.

Focuses on the design, fabrication, and assembly of lawn care equipment, gardening tools, irrigation systems, and related accessories. Prioritizes durable, ergonomic solutions for both consumer and commercial horticultural needs.

Lawn & Garden

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

Echo Molding, Inc. produces custom plastic parts and assemblies for pet-care products, delivering durable and safe components for accessories used in lawn-and-garden environments.

Echo Molding, Inc. provides precision molded components and assemblies for toys, ensuring safe, high-quality parts suitable for children’s products and recreational applications.

Structural systems, conveyors, automated storage & retrieval (AS/RS), forklifts, and palletizing equipment that keep distribution centers and production plants moving. Designs emphasise throughput optimization, ANSI/RIA safety standards, and rugged, 24/7 reliability for intralogistics operations.

Logistics, Warehousing & Material Handling

Echo Molding, Inc. supports transportation and delivery industries by manufacturing precision injection-molded parts and assemblies used in logistics equipment and material-handling systems.

Echo Molding, Inc. fabricates precision plastic components and assemblies for electronics and semiconductor applications, supporting enclosures, housings, and structural parts with high-quality molding and assembly.

Involves the design, fabrication, and assembly of equipment for various sports. Combines innovative materials, precision engineering, and safety considerations to produce protective gear, training accessories, and performance-optimized sports equipment.

Sporting Goods

Echo Molding, Inc. manufactures precision injection-molded parts and assemblies for sporting goods, delivering durable and performance-optimized components for athletic applications.

Echo Molding, Inc. supplies precision molded components for military ground-vehicle and defense-system applications requiring robust and reliable parts.

Echo Molding, Inc. produces injection-molded components and assemblies for lawn and garden equipment, supporting durable and ergonomic tools and accessories for horticultural use.

Custom freestanding, countertop, and inline display fixtures, end-caps, and branded signage fabricated from sheet metal, plastics, wood, and composites to merchandise products in retail settings. Priorities include rapid prototyping, graphic integration, knock-down shipping formats, and durability for high-traffic store use.

Point-of-Purchase (POP) & Retail Displays

Rigid, flexible, and specialty packaging; high-speed printing and labeling technologies. Efficiency, sustainability, and regulatory compliance drive solutions that protect products and communicate brand value across FMCG, pharma, and industrial supply chains.

Packaging, Printing & Labeling

Echo Molding, Inc. produces injection-molded brackets, housings, and signage components for custom point-of-purchase and retail display fixtures, enabling rapid national rollouts for brand merchandising.

Echo Molding, Inc. manufactures injection-molded components and assemblies for lottery and point-of-sale systems, supporting durable and precise parts for retail transaction and promotional equipment.

Founded in 1975 and still family-run, ISO 9001:2015-certified Echo Molding, Inc. provides custom injection-molded parts, tooling, and turnkey assembly from its single facility in Union Township, NJ. Serving customers across the Mid-Atlantic and Northeast, the company runs 25 automated Nissei presses (90 – 950 tons) alongside an in-house tool room, taking projects from design through packaged product. Solar-powered operations and lights-out automation help Echo deliver cost-efficient, high-quality parts for automotive, medical-device, telecom, and consumer-product markets.

Echo’s 65,000-ft² headquarters sits just off I-78 in Union Township, Union County, a few miles west of Newark Liberty International Airport and Port Newark-Elizabeth. The solar-powered facility houses 25 Nissei presses (90 – 950 tons), 21 six-axis robots, and a full CNC tool room for on-site mold design and maintenance. Integrated assembly, decoration, and packaging lines enable same-site production and same-day truck service to nearby hubs such as New York City and Philadelphia under an ISO 9001:2015 quality system.

Echo Molding Headquarters

Leader in custom injection molding with ISO 9001:2015 certification and full-service assembly.

Echo Molding

Custom Injection Molding and Assembly

Advanced Plastic Injection Molding

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