Precision Injection Molding at Tessy Plastics involves high-volume molding of complex thermoplastic, thermoset, and liquid silicone parts with tight tolerances and excellent repeatability. Utilizing advanced hydraulic, hybrid, and all-electric presses with real-time process monitoring, Tessy delivers consistent, high-quality components for medical, consumer, and industrial applications.

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

Precision Injection Molding

Tessy Plastics provides custom automated assembly solutions integrating multi-axis robotics, vision systems, and smart fixtures for efficient, high-quality product assembly. Automation includes pick-and-place, press-fit staking, ultrasonic welding, and in-line functional testing, enabling takt times below 2 seconds per part with full traceability and quality control.

Robotic Assembly integrates multi-axis robots, vision guidance, smart fixtures, and in-station testing to perform fully automated, sequential assembly of discrete products. Typical tasks include pick-and-place insertion, press-fit staking, adhesive or ultrasonic welding, functional verification, and on-the-fly marking. Lines achieve takt times below 2 s/part while capturing traceable QC data for every unit built.

Robotic Assembly

Custom Automated Assembly

Tessy offers comprehensive tooling design and build services, engineering specialized molds, dies, and fixtures to achieve precision, repeatability, and optimized production efficiency. The tooling team utilizes advanced CAD/FEA tools and maintains high standards for material selection, dimensional accuracy, and tool life to support complex manufacturing requirements.

Tool & Die manufacturing designs, machines and validates progressive-stamping dies, plastic-injection molds, hydroforming dies, welding fixtures and precision inspection gages. Shops integrate 5-axis machining, Wire/Sinker EDM, jig grinding and CMM verification to achieve ±0.0002 in feature positions and micro-polished shut-offs for multi-million-cycle production.

Tool & Die (Fixtures & Gages)

Tooling Design and Build

Post-Molding Operations at Tessy include precision mechanical assembly, staking, adhesive bonding, and kitting services. These operations ensure assembled sub-components meet torque, cleanliness, and functional specifications, supported by advanced inspection and traceability systems to deliver turnkey, line-ready products.

Assembling involves putting together various metal components to form a complete unit. This can include methods like welding, riveting, and using threaded fasteners.

Assembling

Post-Molding Operations

Tessy’s Quality Control and Testing processes ensure all products meet stringent specifications and regulatory standards through visual inspections, dimensional checks, non-destructive testing, and automated systems. Advanced metrology equipment and statistical process control maintain high product integrity and compliance across all manufacturing stages.

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

Quality Control and Testing

Tessy’s Engineering and Product Development offers end-to-end technical services bridging design intent with production. Services include CAD data import, DFM reviews, 3D modeling, CAM programming, fixture design, and revision-controlled documentation. The team supports rapid prototyping, finite-element analysis, and continuous improvement to optimize manufacturability and cost-effectiveness.

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

Engineering and Product Development

ISO 13485:2016 specifies requirements for a quality management system for medical device manufacturers, emphasizing regulatory compliance, product safety, risk management, and traceability throughout the lifecycle of medical devices.

ISO 13485:2016

U.S. FDA clearance confirming that an additive used in food-contact packaging or processing equipment is safe under intended conditions of use, as demonstrated through a Food Contact Substance Notification (FCN) or applicable 21 CFR indirect additive regulation.

FDA Food Contact Substance (FCS) Clearance

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

Tessy Plastics manufactures precision-engineered medical devices and critical healthcare components using advanced injection molding, automation, and assembly processes to meet stringent FDA and ISO 13485 standards for medical applications.

Equipment, consumables, and turnkey systems for small-molecule, biologic, and advanced-therapy manufacturing. cGMP facilities, sterile environments, and automated bioprocess controls enable compliant, high-purity drug production from R&D scale to commercial output.

Pharmaceuticals & Biotechnology

Tessy Plastics provides contract manufacturing services for pharmaceuticals and biotechnology, including precision fabrication, automation, and assembly of drug delivery systems and packaging in cGMP and sterile environments.

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

Tessy Plastics delivers high-quality manufacturing and automated assembly of consumer goods and healthcare products, including personal care and hygiene items, leveraging precision molding and turnkey production solutions.

Tessy Plastics Corp., founded in 1973 and headquartered in Skaneateles, NY, is a global contract manufacturer specializing in precision injection molding and custom automated assembly solutions. With over 3.2 million square feet of manufacturing and warehouse space, including 320,000 square feet of ISO Class 7 & 8 clean room manufacturing, Tessy serves the Medical, Pharmaceutical, Diagnostics, Consumer, and Consumer Healthcare markets. The company holds key certifications such as ISO 13485 for Medical Devices, ISO 14001 for environmental management, and FDA/GMP registration. Tessy offers comprehensive capabilities including product design and development, rapid prototyping, tool design and build, medical automation design and build, plastic injection molding, and complex device assembly. Their facilities are equipped with advanced quality control tools and they emphasize continuous improvement, sustainability, and regulatory compliance to deliver superior quality and speed to market.

Headquarters with over 3.2 million square feet of manufacturing and warehouse space, including 320,000 square feet of ISO Class 7 & 8 clean room manufacturing. Equipped with advanced injection molding presses and comprehensive engineering and R&D facilities, providing superior quality and speed to market.

Tessy Plastics Corp Headquarters

Wholly owned foreign entity providing manufacturing operations in China to support global customers.

Tessy Plastics Shanghai Ltd.

Custom automation integrator facility supporting manufacturing automation solutions.

Tessy Automation, LLC

Custom tool manufacturing facility supporting in-house tooling design and build capabilities.

Tessy Tooling, LLC

Global contract manufacturer specializing in precision injection molding and automated assembly for medical and consumer markets.

Tessy Plastics

Precision Injection Molding And Automated Assembly

Precision Injection Molding

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Technical Capabilities

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