Molding Capabilities & Markets


Molding Expertise Very few companies consider or have the ability to involve themselves in projects that require all aspects of plastic part production. Each step in the process, from concept design to product delivery, is integral to success. Failure to effectively apply any component of the process can result in program failure. Hawk associates have extensive experience in:

-Product Design and Development
-Material Selection / Characterization
-Tight Tolerance Molding
-DOE's / High Speed Data Acquisition
-Tool Design
Our market focus are aerospace, telecommunications, medical, and fuel cell industries. Our 
ultimate goal is to provide an integrated solution incorporating all engineering disciplines 
at a competitive price. This is how we define value.
Hawk Integrated Plastics' associates apply the following advanced technologies:
Process Technologies: 
High Speed Data Acquisition
Using external high speed data acquisition to “center” the process and develop the largest 
process window, sensitivities in the process that have the most effect on part quality can be 
understood, modified, and controlled more efficiently.
Hawk Integrated Plastics associates have worked with industry-leading data acquisition equipment
 manufacturers to design, develop, and test equipment produced specifically for the 
molding industry.
Design of Experiments (DOE)
Hawk Integrated Plastics applies statistical Design of Experiments methods in conjunction 
with high-speed data acquisition to efficiently determine the sensitivities that affect part 
quality in an injection molding process. This is the basis of our quality approach: 
Quality gates applied early in the process will eliminate inspection needs downstream. 
While the industry typically relies on Statistical Process Control (SPC), we at Hawk refer to 
our approach as “On-line Statistical Quality Control” (OSQC). This approach allows us to 
statistically determine the dimensions of a part without ever physically measuring the part. 
Cavity Pressure Sensing 
Pressure sensing transducers placed in the cavity of a tool can be used to monitor the 
pressure drop (Delta P) across the part geometry during the fill, pack, and hold phase of 
the molding process. This gives an immediate and clear picture of process repeatability and 
part quality in the mold. (OEM’s are requesting this technology, but there remains little 
understanding in the industry). Hawk associates have used this technology for over a decade,
 and have developed comprehensive, robust processes for the efficient use of cavity pressure 
Lights-out Molding 
In a lights-out facility, the molding process is completely automated. Hawk Integrated Plastics 
associates have developed robust injection molding processes and tooling for novel lights-out 
molding operations. Lights-out molding operations using process windows identified through 
high-speed data acquisition and Design of Experiments will be the focus for high volume 
consumer products. Hawk Integrated Plastics has the technology to develop state-of art lights-out facilities.
Cooling Efficiencies 
Appropriate cooling design and the resultant thermal efficiency for injection molding tooling 
is critical for dimensionally stable plastic parts. Hawk associates have over twenty combined 
years of experience developing and applying efficient cooling designs for injection molding 
tools (patents pending).Conformal cooling studies: several joint efforts with Universities 
(MIT, UConn, UMass) and industry (AMP, Motorola, Ford, Chrysler, etc.). 
Mold Filling Analysis 
Mold filling analysis helps tool designers save time and money during the design process. 
Appropriate gating schemes, channel sizes, and cooling designs can be optimized before any 
machining of tool steel. Hawk associates have twenty combined years of experience developing 
and applying computer-aided engineering (CAE) to the injection molding process. 
(C-Mold, Mold Flow, etc.) (Patents pending)Hawk Integrated Plastics has World-Class capability 
for interpretation of computer-aided filling analysis, including gas-assist injection molding.
Hot Runner Technologies 
Hot runners are used to control polymer melt temperature between the molding machine barrel 
and the gate of the mold. This allows for process repeatability, sophisticated tool design, 
and saves material costs because there no sprue and runner system is required.
Hawk Integrated Plastics associates have benchmarked and worked with industry leading 
manufacturers to develop new valve gating technologies, cooling techniques, and manifold designs.
Special Processing Technologies 
Gas-Assist Injection Molding 
Gas-assisted molding is a technique that allows for the evacuation of polymer during the 
molding process by injecting dry nitrogen into the polymer path to create a hollow part.
Hawk Integrated Plastics associates have worked with industry leading manufacturers to develop
 new controller technologies, gas pin designs, and processing techniques. Hawk associates have
 performed years of process and benchmarking studies for gas-assist molding, and has an alliance
 with a leading equipment manufacturer / supplier.
Hawk’s business model requires that we use state-of-art molding and analysis equipment. We only
 employ equipment capable of meeting our requirements of delivering highest quality and 
consistent results. Our equipment list includes: 
·Krauss-Maffei 2-platen injection molding with clamp tonnages ranging from 65 to 420 Metric 
Tons (72 to 465 US Tons, respectively).
-Toyo 90 Ton injection molding press
-Comet and Conair hopper-dryers
-Nicollet Data Acquisition Systems
-Dynisco pressure transducers
Bauer microprocessor-controlled Gas-Assist Injection Unit. Hawk is implementing a computer 
based Preventive Maintenance tracking system to ensure continued functionality and consistency.