Specialty Commercial

Consumer

Consumer Design
From cell phones to power drills, sports equipment to bath fixtures, Phillips-Medisize’s expertise in the development of consumer products makes us an industrial design and engineering resource of choice for the most respected OEMs in the marketplace.

Utilizing a design-through-manufacturing approach, we develop concepts from drawing board to packaged product.

Consumer Development
Phillips-Medisize’s state-of-the-art manufacturing capabilities, combined with extensive knowledge and experience in material selection, have set the bar for consumer products with optimal performance, size and aesthetics.

With resident experts in traditional plastic injection molding as well as multi-shot, metal, magnesium, thin wall, windows, and decorating, Phillips-Medisize is known as a one-stop shop for the design and development of some of the most well known consumer products in the marketplace.

Multi-Shot molding
Characterized as producing high performance yet aesthetically pleasing parts, multi-shot molding creates parts using two or more grades or colors of resin to reduce the number of parts requiring assembly and to achieve durable, molded-in graphics and soft grips on handheld tools and devices.

Product examples include components for Sharpie™ markers, the Segway™ Human transporter, Sonicare™ electric toothbrushes, Moen shower heads, Black & Decker power drills, and Evans Rule tape measures.

Metal Injection Molding (MIM)
Used as an alternative to die casting, MIM allows for the production of small components requiring near wrought strength. Tight tolerances can be achieved on parts with complex, intricate features while maintaining cost parameters. Examples include racing bike shoe clips and scrapbook tools.

Magnesium Injection Molding (MAG)
Weighing in one-fourth lighter than steel and one-third the weight of aluminum, parts produced using the MAG process (also known as Thixomolding®) can be found in electronics, hand-held devices, and sports equipment. MAG is quickly becoming the capability of choice for the production of consumer products that require dimensional precision, thin walls, and lighter weights.

Thin Wall Molding
Consumer OEMs rely on Phillips-Medisize’s expertise in plastic and magnesium thin wall molding to develop housings that protect circuitry from the environment and user. With practical experience in materials, part and tool design, and high-speed processing equipment, Phillips-Medisize is able to mold uniform walls as thin as 0.040″ that can withstand even the most extreme conditions.

Lenses
LCD lenses can be found in a wide variety of consumer products from cell phones to glucose meters to hand-held games. To meet the needs of these diverse applications, Phillips-Medisize has developed several processes for the production of lens displays. Phillips-Medisize’s program managers partner with OEMs to select and optimize the most advantageous method for each application.

Decorating
Phillips-Medisize understands that aesthetics are just as critical to the success of a consumer product as size and performance. Our ever increasing range of decorating options includes painting, laser etching, in-mold decorating, electroplating, pad printing, multi-shot molding, hot stamping, printed appliqués, and our proprietary FORM/INTEGREL® process.

Consumer Product Manufacturing
With over 145,000 square feet of production space, Phillips-Medisize is equipped to handle high volume programs that number in the millions. By employing automatic material supply, close tolerance injection molding presses, process monitoring systems, and custom automation for assembly and packaging, Phillips-Medisize is able to ensure compliance to quality requirements.

Quality requirements include tight control to specifications, and part repeatability for high-volume and high-cavitation production. Phillips-Medisize also has the ability to provide extensive product testing in the areas of shock and vibration, sealing, temperature, humidity, and chemical resistance. Utilizing a lean manufacturing operational strategy, the entire product development process is streamlined to improve profitability, customer satisfaction, and lead times.

Program Management
Adhering to Six Sigma quality efforts corporate wide, Phillips-Medisize’s project teams strive to meet or exceed your expectations for quality, cost, delivery, and overall service.

Phillips-Medisize program management ensures your product is on the market quickly, efficiently, and profitably through:

• Seamless flow-through from concept to production
• Coordination and support of programs that may involve multiple tools, technologies and facilities
• Efficient internal and external communication with the highest level of confidentiality
• Primary customer contact for overall program specifics
• Global, customer-oriented perspective
• Cross-functional teams including customers, designers, engineers, manufacturing and suppliers

Automotive

Automotive Design
From actuators and radio assemblies to sensors, switches, and instrument cluster components, Phillips-Medisize’s expertise in the automotive market makes us a knowledgeable and trusted resource for the successful development of concepts from drawing board to assembled product.

The best design for automotive manufacturing
At Phillips-Medisize’s two design development centers, our experienced team members facilitate seamless project flow through industrial design, design engineering, CAD, finite element analysis, Moldflow® analysis, rapid prototypes, models, and stereolithography.

Automotive Development
By employing value-added work cells that include automatic material supply, close tolerance injection molding presses, process monitoring systems, and custom automation for assembly and packaging, Phillips-Medisize is able to ensure adherence to rigorous ISO 9001 and TS 16949 quality standards, tight control to specifications, and part repeatability for high-volume and high-cavitation production.

Metal Injection Molding (MIM)
In addition to plastic, Phillips-Medisize has been working with the metal injection molding process for over 16 years. Known for producing functional components with highly complex features, superior surface finishes, excellent corrosion resistance, a reduced need for secondary operations, and material properties comparable to wrought, MIM is widely accepted as a cost-effective alternative to the die casting, investment casting, machining, and press and sinter processes. Read more

Decorative applications
Phillips-Medisize continues its commitment to unsurpassed quality, while addressing increased demand for exceptional decorative finishes, including laser etching, in-mold decorating, electroplating, pad printing, multi-shot molding, and hot stamping, all of which are complemented by automated assembly, testing, and distribution to complete program requirements.

Functional applications
From under-the-hood components found in pressure monitors to plastic and metal molded parts for steering and braking systems, Phillips-Medisize’s complete capabilities provide a one-stop-shop for functional molding applications.

Automotive OEMs rely upon Phillips-Medisize’s expertise in functional molding to consolidate components and enhance product functionality and ease of assembly. Phillips-Medisize is able to expedite the manufacturing process without compromising quality by utilizing smart work cells, which include RJG process monitoring systems, automated in-line quality tests, and robotic acceptance or rejection systems.

Automotive Manufacturing
With over 437,700 square feet of manufacturing space, Phillips-Medisize is equipped to handle high-volume programs numbering in the millions.

With strict adherence to lean manufacturing, the entire product development process is streamlined to improve profitability, increase customer satisfaction, and minimize lead time.

Program Management
With extensive experience in design through manufacturing, decorating, and assembly and strict adherence to Six Sigma quality efforts corporate wide, Phillips-Medisize project teams have just one goal in mind – to meet or exceed customer’s expectations for quality, cost, delivery, and overall service.

• Supply chain management development
• Test method development, support, and execution
• Design verification product builds

Defense

Defense Design
Advancements in technology and design give our U.S. military the competitive edge. Because U.S. combat soldiers typically carry more than 80 pounds of equipment with them, they have to be sure that the items will work properly when needed, are durable enough to withstand harsh conditions, and are designed with safety and efficiency in mind.

The best design for defense
At Phillips-Medisize, we design and deliver innovative solutions for the defense market by producing components and turnkey solutions that meet ergonomic and environmental requirements in the field. We provide defense product design and prototyping services using a wide range of materials and methods to meet the strictest requirements for performance, durability and weight.

Defense Development
Your defense project will be overseen by a dedicated team of cross-functional experts who thoroughly analyze and optimize program parameters.

Program managers oversee the entire development process and provide supply chain management. At the same time, we ensure full traceability, documentation and serialization. Our capabilities and dedication combine to help us innovate while achieving high-performance solutions that meet all military standards.

Defense Manufacturing
At Phillips-Medisize, our streamlined product development and manufacturing processes help you achieve your budget and timeline without sacrificing quality.

In addition, our blend of secondary operations, including painting, laser etching, EMI/RFI shielding, plating and a blend of proprietary and non-proprietary coatings, can help you successfully camouflage, protect valuable electronic transmissions and prevent harmful corrosion of metals.

Program Management
Phillips-Medisize has a proven history of handling customers’ defense programs with the dedication, pace, quality and MIL-STDs that meet their needs. With more than four decades of experience in military manufacturing program management, we have the knowledge and expertise to ensure your product is developed quickly, efficiently, and profitably:

• Seamless flow-through from concept to production
• Coordination and support of programs that may involve multiple tools, technologies and facilities
• Efficient internal and external communication with the highest level of confidentiality
• Primary customer contact for overall program specifics
• Global, customer-oriented perspective
• Cross-functional teams including customers, designers, engineers, manufacturing and suppliers