Currently Thunderbird Molding operates more than 125 injection molded presses ranging from 40 Tons to 1550 Tons machine capacity with automation and robotics throughout our manufacturing process. Collectively we operate 5 manufacturing facilities across the United States. Our Class 7 Cleanroom (Class 10,000), ISO 13485: 2016 facility is in Greensboro NC.

Capabilities include:

      •     Insert molding for tight-tolerance plastic parts        •    Two-shot molding for one-of-a-kind parts

      •     Over Molding for a variety of parts and solutions

Finishing Services:

      •     Sonic welding                                   •    Kitting and custom packaging           •    Buffer warehousing

      •     Pad-printed                                        •    Turnkey assembling and inspection

      •     Laser etching and hot stamping    •    Long term agreements

Customized Finished Product:

      •     Multiple-head hot stamping                                                          •    Customized labeling

      •     Multiple-head pad printing                                                            •    In-mold decorating

      •     Screen printing (Within Thunderbird family of Companies)

      •     Sheet-fed, flatbed, and roll-to-roll printing (Within Thunderbird family of Companies)

      •     Large-format printing and laminating (Within Thunderbird family of Companies)

      •     Flatbed-digital, die, and rotary cutting (Within Thunderbird family of Companies)

In-House Mold Design and Tooling Expertise:

 • Internal mold design and manufacturing      •    Cores and cavity inserts         •      Mold repairs 

      •     Rapid and reliable transfer tooling                 •    Internal tooling audit               •    Tight tolerances  

      •     Prototype tooling to production tooling        •    Moldflow and warpage analysis

3D Printing:

      •     Fit checks                                 •    Fixtures                              •    End-use production                        

      •     Material testing                      •     High surface finishes        •    Marketing samples

      •     Master patterns                      •    Part accuracy                     •    Heat, moisture resistance

      •     Rapid tooling                           •    Durability testing  

Materials used for 3D Printing:

      •     Rigid Polyurethane versatile—tough, rigid, UL 94 HB

      •     Flexible polyurethane—impact-resistant

      •     Elastomeric polyurethane—highly elastic, tear-resistant and resilient

      •     Epoxy—temperature-resistant, strong, accurate

      •     Urethane methacrylate—fast, accurate, custom colors for prototyping and manufacturing jigs and fixtures

      •     Silicone—soft touch, biocompatible and tear-resistant for wearables such as wristbands

Quality Control:

·        ISO 9001:2015                                      •    UL                                    •    Accommodate Special Testing

·        ISO 13485:2016                                    •    FAI                                          

·        FDA Registered                                     •    PPAP and SPI Compliant

·        ISO 7 (Class 10,000) clean room         •    Medical Validations - IQ OQ PQ