Process
A Proven Path from Concept to Completion
At United Plastic Components, we don’t just make extruded plastic parts — we make the extrusion process seamless. Whether you’re arriving with a sketch, a prototype, or a fully engineered CAD drawing, our structured, collaborative process is designed to take your concept from idea to finished product with clarity, consistency, and speed.
Our end-to-end workflow combines cross-functional expertise with full in-house control over design, tooling, production, and quality. The result? Smoother communication, faster turnaround, fewer delays, and better parts.
Step 1: Discovery & Requirements
Every successful project starts with understanding. Our first job is to listen — to learn what you’re trying to achieve, how your part will be used, and what constraints you’re working within.
Whether you’re a design engineer, a buyer, or a product manager, our team will work with you to define:
- Functional and performance requirements
- Dimensional tolerances and mating part interfaces
- Appearance, color, and surface finish needs
- Material and regulatory considerations (e.g., UL, RoHS, FDA)
- Expected volumes and packaging preferences
We can review your CAD files, help you develop prints, or even reverse-engineer legacy parts if drawings are unavailable.
Step 2: Design & Engineering
With your requirements defined, our in-house engineering team develops a manufacturable profile and designs the tooling needed to produce it. We use advanced 3D modeling software to design all tooling and punches in house
Our engineering process includes:
- Profile design and CAD modeling
- Resin selection guidance based on performance and processability
- Die and tooling design for optimal flow and cooling
- Review meetings for customer approval before tooling build
This stage ensures that your part is not only functional but also efficient to produce, reducing cost and cycle time.
Step 3: Tooling Fabrication
All primary and secondary tools are built in-house at our Tool & Die Shop, giving us tight control over precision, timeline, and process fit. Our tooling team works hand-in-hand with engineering to ensure everything — from die to downstream fixtures — is purpose-built for your profile.
This includes:
- CNC-machined stainless steel extrusion dies
- Vacuum calibration blocks and water tanks
- Inline punching dies, cutoff tools, and sizing fixtures
- Labeling, taping, or adhesive application stations
By building everything under one roof, we streamline integration, minimize trial delays, and ensure that tooling supports your production goals from the start.
Step 4: Line Setup & Trial Run
Before full production begins, we configure and optimize the extrusion line specifically for your part. With seven main extruders and portable co-extruders for multi-material profiles, we tailor every element of the process — from screw type to downstream cooling — to suit your application.
Trial runs allow us to:
- Dial in temperature zones, line speeds, and vacuum levels
- Verify dimensional stability and surface finish
- Identify and resolve any design-to-production misalignments
- Capture first-article inspection data for approval
Our goal is to ensure your part meets spec before the first full order even begins.
Step 5: Production & Post-Processing
Once your process is validated, we move into production. Our experienced operators and technicians manage every run with a focus on consistency and real-time quality control. We also offer a wide range of inline and secondary services to prepare parts for downstream use or immediate shipment.
Capabilities include:
- Cutting to length, slitting, or notching
- Drilling, punching, or routing
- Inline labeling, taping, or printing
- Custom packaging, kitting, and barcoding
- Collaborative quality reviews and improvement initiatives
We adapt our production system to your needs — whether that’s high-volume throughput or small-lot flexibility.
Step 6: Quality & Final Inspection
Before any parts leave our facility, they undergo a rigorous quality check in our on-site lab. Dimensional checks, visual inspections, color matching, and performance validation are all part of our ISO 9001:2015-certified process.
We maintain:
- Complete batch and material traceability
- Retained samples for reference and validation
- Documentation packages including CoCs, inspection reports, and more
- Re-certification processes for repeat orders
Our commitment to quality ensures you receive reliable, production-ready parts — every time.
Step 7: Packaging & Delivery
The final step is delivery — but we treat it with the same care as every other stage. Our team ensures your parts are packed securely and labeled clearly for easy identification and traceability.
Options include:
- Bulk or compartmentalized cartons
- Custom crates, coils, or reels
- Barcoded labels with part numbers, lot codes, and dates
- Warehouse staging for JIT or scheduled shipments
Whether you need retail-ready packaging or bulk industrial supply, we’ve got you covered.
Let’s Build Something Better, Together
Our process is about more than making parts — it’s about building partnerships. With clear communication, technical expertise, and full in-house control, United Plastic Components makes the path from concept to completion smooth, transparent, and reliable.
Request a Quote Today!
Ready to bring your custom plastic extrusion project to life? Our team at UPC is here to provide you with a fast, accurate quote that fits your exact needs. Whether you're working on a small project or large-scale production, we'll ensure a seamless process from start to finish.
