Injection molding is the ideal manufacturing process for producing high-precision plastic components with complex geometries, thin walls, and tight tolerances—at scale. At Pexco, we specialize in molding ultra and high-performance thermoplastics using a unique combination of advanced mold flow analysis, proprietary tooling systems, and deep material expertise. This allows us to eliminate or significantly reduce secondary operations, improving part quality and reducing total cost. Whether you’re developing a part that pushes design limits or requires demanding thermal, chemical, or structural performance, we bring the technical capability to make it moldable—and manufacturable.

Net shape molding is the precision manufacturing process of producing highly complex parts with near-final geometry, minimizing or eliminating the need for secondary machining. At Pexco, we integrate advanced solid modeling (SolidWorks, STEP, Parasolid, IGES), mold flow analysis, and finite element analysis with our proprietary true form sizing technology. By combining 3D CT scanning—capturing over 1.2 million internal and external dimensional data points—with custom CAD/CAM-driven tool modification, we deliver exceptionally tight tolerances and best-in-class part fidelity. This process is ideal for mission-critical components like seals and valve bodies, where precision down to ±0.0003″ and smooth surface finishes are essential. The result is high-performance, net-shape molded parts that reduce cost, improve throughput, and meet the most demanding dimensional specifications.

Insert molding allows the integration of metal, ceramic, or other pre-formed components directly into the injection molding process, creating a single, unified part. At Pexco, we have pushed the boundaries of insert molding with proprietary tooling, advanced fixturing, and precision robotic placement systems that enable consistent overmolding of delicate or complex inserts. Whether manually loaded or fully automated, our process ensures the polymer flows securely around even the most challenging features. We work extensively with both filled (graphite, glass, carbon fiber) and unfilled high-performance thermoplastics, delivering enhanced part strength, reduced assembly time, and superior bond integrity. Insert molding  provides for greater design flexibility, enabling customers to build next-generation components with fewer steps and lower cost.

Injection Molding complex components from ultra- and high-performance plastics—like fluoropolymers and PEEK—can be cost-prohibitive using conventional methods. Pexco solves this challenge with our direct-gated, multi-cavity tooling technology, designed to reduce material waste, cut per-part costs, and make advanced materials more accessible.

Our proprietary direct gating process injects polymer directly into each part cavity, eliminating traditional runners. This is especially critical when working with shear-sensitive and costly materials like FEP, PFA, PVDF, and PEEK, where minimizing waste and degradation is essential.

Compression molding is ideal for producing strong, high-integrity parts from thermoset, high-performance materials, especially when tolerances structural integrity are critical. At Pexco, we use precision-matched metal tools, heat, and pressure to mold advanced resins into complex forms without the need for injection for further finishing. This process is particularly well-suited for low- to medium-volume production, large or thick-walled parts, and components with challenging material properties. Our expertise in compression molding extends to materials such as phenolics, epoxies, polyesters, and high-temp thermosets, enabling us to meet tight dimensional tolerances and deliver reliable mechanical performance across demanding applications.