Injection Molding

Design, Prototype & Tooling

Prototyping injection molded dunnage, prior to building production tooling, helps to protect the customer from costly tool changes later in the program. The prototypes are typically constructed of production-like materials so that the customer may quickly evaluate the effectiveness of the package. Sur-Form offers cost-effective and timely prototype solutions for its customers.

Bar Dunnage

Bar dunnage is an easy to install solution that is widely used in the material handling industry to provide separation and protection between the customer’s parts. Sur-Form can produce bar dunnage with different Shore hardness depending on specific requirements.

Sur-Form can also provide 3-D Printing of prototype dunnage to shorten longer lead times on CNC cutting of plastic components where testing may not be necessary.

Flipper Dunnage

“Flipper” Dunnage is a type of dunnage that is utilized when the customer requires a top lock-off or side lock-off and a need to maintain full product separation. This dunnage typically consists of multiple finger-like details that pivot independently on one axis that are flipped open to allow the material handling operator to load the product, and flipped closed to lock the product in place. Flipper Dunnage systems interface well with automated loading and unloading systems or robotics.

Sur-Form also has extensive experience with a two-part molding process known as over-molding. This two-part dunnage consists of a hard plastic substrate with a softer material molded on surfaces that is in contact the product. The hard plastic provides structure to the dunnage while the softer, rubber-like plastic, provides extra protection and cushion for the product.

Insert molding is utilized in the most demanding dunnage applications where a sharp, unfinished metal edge of the part contacts the plastic dunnage. Stainless steel wear plates are molded into the dunnage and virtually eliminate dunnage wear due to heavy point loads. Insert molding can dramatically extend the life of the dunnage and reduce container repair costs.

Shipping Trays

Sur-Form supplies a variety of custom injection molded trays for the material handling industry including shipping and processing trays, kit trays, and precision automation trays. Tray sizes range from 1/48 to 1/2 size, based on a 45″ x 48″ standard base pallet.