Precision Injection Molding

Empire Precision Plastics specializes in precision injection molding of close-tolerance optical and precision plastic parts using a broad selection of engineering resins.

Engineers and program managers value us for our knowledge, trusting Empire to improve system manufacturability and ensure total program success. Buyers appreciate the range of in-house services and our tool storage and in-house mold maintenance service.

Let our positive, problem-solving business approach bring that extra edge to your next program:

• Expertise in highly complex tools. Extensive engineering staff ensures design for manufacturability across the assembly.
• Complete mold maintenance services: In-house, full-service tool room and dedicated staff members.
• Extensive and up-to-date equipment: Current equipment includes 40 microprocessor-controlled injection molding machines, with over 80% automation. Thermo and valve gate hot manifold systems. Electric and advanced hydraulic molding machines.
• Process monitoring and back-up: Temperature or pressure in-mold sensors. Redundant systems for key mechanical procedures such as compressed air and process water systems.
• Controlled environment: Air-conditioned factory, chilled and heated mold temperature control and white room facilities.

Reduce Assembly Cost & Defect Rate

Integrated, in-house capabilities, automation, and white room assembly results in better quality at a lower cost. Our facility contains a modern white room environment as well as molding equipment and all the metrology expertise necessary to produce highly sophisticated optics and optical systems. We use robotics to produce high volumes at reasonable prices for automation-friendly assemblies. Low volume to high volume, our people and equipment stand ready to design, manufacture, and test optics in record time.

Process Pedigree

Empire Precision Plastics maintains world-class quality by beginning with DOE/Taguchi Techniques to design our processes and solutions, and then using Statistical Process Control (SPC) and process capability (CP/CPK) to maintain our standards. Our technology allows us to monitor process control during production and reject substandard components prior to inspection, thus accelerating our throughput.

Choosing the right plastic optical prototype manufacturer and method can help cut time and costs for your injection molding program. Empire offers several options for prototyping both precision plastic parts and plastic optics, each with its own benefits. Often a combination of these methods is used leading up to full-volume production.

Whether you require small volumes or a quick ramp-up to full production, Empire will work with you to determine the best approach for your plastic prototype parts services.

Prototype Tooling

Often, following one of the other prototyping methods, prototype tooling involves the same gating, ejection, and cooling procedures as will be applied in full production. Once the final design is established, production-intent prototypes are created using rigorous Scientific Molding processes. This type of tooling is necessary for high-volume injection molding programs.

Rapid Tooling

Some customers prefer a rapid tooling option in which they own the tool. Considered a prototype tool, aluminum tooling allows customers to easily move into full-volume production. Rapid tooling allows for easier design and mold changes, more resin choices, and higher-volume runs. Parts can also be grouped in a family tool for greater cost savings.

Precision Machining

Precision machining is a subtractive method of prototyping that uses CNC mills and lathes to shape stock materials. This option is useful for low-volume runs and is typically low cost and high quality.

Single Point Diamond Turning (SPDT)

Single Point Diamond Turning (SPDT) is an optical manufacturing process that is useful for producing low to moderate volumes of high-quality plastic optics, most commonly used for prototyping and R&D projects. This is accomplished by utilizing a precision CNC lathe with a diamond cutting tool specifically designed to cut the surface geometry of the lens. Using a CNC lathe makes the process consistently repeatable to create uniform parts ready for coatings. SPDT can be used for aspheric lenses as well as optics with more complex features.

Along with the ability for rapid prototyping, SPDT allows for plastic optical designs to be created without the added first step of building an expensive injection mold. This can also be useful in helping our customers meet early demands before moving to full-scale production. 2-4 week turnaround times are completely achievable with this process.

Empire’s SPDT boasts a Moore Nano 350; with a resolution of 0.4µ” (10nm) coupled with onboard profilometry, Empire Precision’s technicians can generate and verify optical surfaces in real-time, with surface and form accuracies to the sub-micron level and surface roughness measured down to the angstrom level.

Single Point Diamond Turning is a fantastic choice for a customer looking for faster production/delivery, reduced tooling costs, with high quality at lower volumes. Reach out to us and see how Empire can make your next project take shape

Empire Precision continues to expand its robotics, offering automated injection molding technology for high-volume plastic parts. Empire’s automation is an ideal fit for medical devices and other products that demand tightly controlled scientific molding processes and precise quality.

Modern Equipment

Our current equipment includes 40 microprocessor-controlled, injection molding machines, with over 80% automation. Empire’s automation systems include servo-driven, multi-axis robotics, streamline part handling, and secondary operations.

Controlled Environment

Empire offers full automation within a cleanroom-controlled environment. Parts enter the cleanroom on a conveyor from the injection molding machine. Fixed, portable, and micro-cleanrooms are available for effective precision molding workflows.

Controlled environment molding has been particularly effective for one customer, whose medical fluid control valves must be protected from particulates in the factory environment due to direct patient contact. By enclosing the automated molding system in a cleanroom, dust and surface contaminants are removed.

Reduce Assembly Cost & Defect Rate

Integrated, in-house capabilities, extensive automation, and white room assembly result in better quality. Our facility contains a modern white room environment as well as state-of-the-art molding equipment and all the metrology expertise necessary to produce highly sophisticated optics and optical systems. We use robotics to produce high volumes at reasonable prices for automation-friendly assemblies. Whatever your needs, our people and equipment stand ready to design, manufacture, and test optics in record time.

Empire is constantly investing in advanced metrology equipment to measure ever-tighter tolerances for opaque and optical parts. Our metrology department currently includes:

Injection Molding Process Metrology

• IQMS Quality Management Software
• Omnimark Mark 3 Material Moisture Analyzer
• Zeiss Calypso Servo-driven CMM
• RJG Process Monitoring
• Dynisco Melt Flow Indexer

Optical Metrology

• Optical Gaging Products SmartScope Flash, 200 and 300 series
• Fisba Optik Interferometer
• Zygo New View 7100 White Light Interferometer
• OptiPro OptiTrace 5000 Contact Profilometer
• Stereo Microscopes
• Video and Optical Comparators

Your program success depends on assemblies and sub-assemblies that are well-aligned, on time, and at the right total cost. Our in-house secondary and assembly services improve your total program cost by improving quality and production time. From the simple assembly of mating components to turn-key electro-optical system assembly of a finished product, Empire provides injection molding contract assemblies that save you time and money.

These services include:

• Pre-launch prototyping for product evaluation
• Custom packaging
• Kitting
• Complete or partial component assembly
• Capability studies and validation

Our assembly services include:

• Full-service molding and assembly solutions
• Work cells operating within the molding cycle
• Manual, semi-automated, and fully automated assembly
• Injection molding with integrated down-stream assembly
• Ultrasonic welding, heat staking, machining, decorating, and testing

Electro-Optical Assembly

Empire Precision Optics is a single-source solution to your most complex and innovative projects. We manufacture and assemble systems that combine electronics and plastic optics, and we work with your engineering staff or our engineers to develop certified, cost-effective electro-optical subsystems for your products. Your volumes and quality standards demand dedicated custom setups. We have the facilities, processes, and capital to accommodate these needs. In most cases, we will specifically design a strategic center within our plant to produce your electro-optical system assemblies. This center offers the specific, highly specialized manufacturing methods and meticulous handling required to ensure the highest quality and most cost-effective product output.

At Empire Precision Optics, you can be sure we will:

1. Fully analyze your proposed electro-optical project
2. Offer engineering design input to reduce manufacturing costs

Our quality policy for injection molding is to develop, produce and deliver on-time products that meet or exceed your expectations.

To do this, Empire Precision Plastics has implemented quality systems, business practices, and manufacturing processes that we continually improve to satisfy our customers’ evolving needs. The quality and continuous improvement guidelines for every employee are as follows:

• The advanced Project Team will work with courtesy and integrity in partnership with our customers to evaluate their needs and develop cost-effective solutions.
• Manufacturing Engineering will provide timely production-capable manufacturing processes that can consistently achieve our customers’ requirements for high quality and capacity.
• Quality Assurance will objectively and meticulously verify products and processes to ensure your satisfaction.
• Manufacturing will ensure that product components and assemblies adhere to standards that meet or exceed our customers’ specifications.
• Customer Service will provide prompt and accurate product delivery.
• Post-Sales Support will provide prompt, courteous, accurate resolution to any customer problems or inquiries. We will continue an ongoing dialog with our customers to determine their evolving needs in a dynamic marketplace.

Empire Precision’s reputation for quality and service is the result of success in all of these areas. Every employee’s actions have implications that reflect on the perceived quality of the entire organization. Each and every employee is responsible for that quality.

Compliance & Certifications

Empire Precision is certified to ISO 9001:2015 quality management standards. This certification offers our customers a globally recognized standard of quality assurance and underscores our commitment to continual improvement.

Empire Precision works hard to ensure that our certifications make your medical device supply chain management and audit process easier.

Empire is ISO 13485:2016 certified for the manufacture of medical devices. This ISO certification covers contract manufacturing of custom injection molded plastic parts, polymer optics, and single-point diamond turning. The certification has been updated to match that of the European Commission, and Empire is already in compliance with the new standards.

Empire Precision currently holds a federal firearms license, FFL #6-16-055-07-5H-05634, from the United States Bureau of Alcohol, Tobacco, Firearms, and Explosives for the manufacture of firearms. Our high standards ensure the best appearance, performance, and quality for polymer firearm parts.

Empire Precision is now registered in compliance with the International Traffic in Arms Regulations (ITAR) for the manufacture and export of products used in industrial applications.

As a provider of injection molded optics, opaque parts, and assemblies for firearms, heads-up displays, night vision systems, and other applications, we can now save our defense customers time during their qualification and audit processes.