When the Best Results Require Overmolding Different Materials....and a Better Supplier-Partner

Plastic Injection Molding Office Furnishings

This world-renowned and rapidly growing Office Furnishings client selected Nelson Miller Group to resolve ongoing quality and delivery issues associated with a past supplier. The products involved in this project included a very popular, high-end office chair system consisting of a glass-filled polypropylene seat, a polypropylene seat back with a different level of glass loading - which was then overmolded with a thick band of TPV resin to provide the right mix of strength and flexibility, and other structural components. Challenges the Nelson Miller Group team had to overcome included managing the logistics of transferring tooling in extremely poor condition with no fabrication documentation from a southern US-based supplier, inspection and acquisition of certified custom resins and colorants in inventory at the last supplier, tooling intake, inspection, documentation, repair and sample test-molding, submission of new First Article Inspection samples for cosmetic and performance approval, and initiating production to eliminate a critical order backlog that had occurred before Nelson Miller Group was called on to help.

All of the above activities were completed in 15 days to the client's delight. The most impressive fact relating to this project is that the mix of product versions totaled 96 unique combinations of seating colors, overmolded resin colors and finally standard and flame-retardant options.