Manufacturers have seen a lot of upward pressure on costs including labor, materials, and freight. To further mitigate non-value-added labor cost from impacting part price, New Berlin Plastics has deployed a new UR20 collaborative robot (cobot) from Universal Robots. Focused on automating tasks for higher tonnage presses, the UR20 adds new capabilities to the automation…

No plastic pellet, flake, or powder left behind. That’s the goal of Operation Clean Sweep. One of New Berlin Plastics’ resin distributors, M. Holland, is totally committed to it and encourages members of its supply chain to do the same. Operation Clean Sweep (OCS) was launched in 1991 to help every plastic resin handling operation…

Electronic Device Casings: Including casings for computers and headphones, the application of PC material provides a solution that is lightweight, durable, and aesthetically pleasing.

Safety Helmets: The high impact resistance of PC makes it an ideal material for manufacturing safety helmets, which are extensively used in construction, sports, and other fields requiring head protection.

Our process, LaunchLogic, can revolutionize your next project launch. The result is a 98% on-time launch track record, achieved over 100 simultaneous open customer projects. - learn more -

Polycarbonate (PC) is an amorphous thermoplastic material, a high polymer containing carbonate groups (-O-C(=O)-O-) in its molecular chain. It is synthesized through a polymerization reaction involving Bisphenol A (BPA) and Phosgene (COCl2). Known as a high-performance thermoplastic, PC is widely used for its outstanding transparency, heat resistance, and impact resistance.

Motorcycles give riders a sense of freedom and power, as well as the satisfaction that they look cool while cruising down the highway. But as bike OEMs continue to engineer new models with advanced performance and eye-catching appearance, there’s another priority impacting their design decisions today – environmental sustainability. One iconic motorcycle manufacturer in the…

New Berlin Plastics, Inc. works directly with industries and organizations who place a value on high quality engineered products and services.  One of our goals at NBP is to work with customers on projects from start to finish. This allows us to create a solid relationship, provide value-added engineering services, and generate the best possible product for the application. Our experience and expertise in custom injected molded plastic components assists customers in various fields and markets:

UL is a standards setting and certification organization. While New Berlin Plastics doesn't have any proprietary products to certify, a number of our customers do. Manufacturers who support customers with UL certified products need to understand the paperwork and labeling requirements associated with producing components and products that hold UL certifications. New Berlin Plastics is familiar with managing and supporting these requirements.

Automation is key to New Berlin Plastics’ success. When we work with customers to develop and launch a project, automation plays a vital role in ensuring we are providing the best possible value.

New Berlin Plastics has always excelled at high-quality plastic molded parts, but new changes to the Quality Department are even increasing on-time delivery of Product and Process Validations (PPAPs) from 96% to 99%. To meet the needs of our growing workload, we’ve enhanced our Quality Department to ensure dedicated support for both our external and…

We recently purchased a new building to stay one step ahead of growing demand from our customers. Here is a brief “inside look” at Building 2.

Our knowledge and understanding of engineering, plastics, and mold-building allows us to manage our overall process and quickly succeed in the creation of your products.

“Our strength is in our team. By working together toward common goals, we outperform our competition and provide our customers with excellent service.”

High and Low Molecular Weight PC: High molecular weight PC has longer chain lengths, typically showing higher strength, better heat resistance, and superior mechanical properties. It’s suitable for high-performance applications like bulletproof materials and high-end mechanical parts. Conversely, low molecular weight PC, with shorter chain lengths, is easier to process and mold but usually means lower mechanical strength and heat resistance. This type of PC is more suitable for general consumer products and non-heavy-duty applications.

Polycarbonate (PC) plays a crucial role in various injection molding products due to its unique characteristics and is widely used in the following areas:

Let’s quickly understand the various types of Polycarbonate (PC) and the nature of modified PC. Modified PC refers to the materials obtained by adding different reinforcing materials or additives to the base PC resin to improve or enhance its original properties. Common types of modified PC include:

Understanding the right parameters for injection molding of PC is crucial for optimal product quality. Here’s an overview:

These modified PC materials, with their unique combination of properties, find widespread applications in various industrial fields. Through modification, the application range of PC has been greatly expanded, meeting more stringent or specific performance requirements.

Transparent PC: Although PC is inherently transparent, specific modifications can further enhance its transparency and optical properties, suitable for optical products and decorative items that require high transparency.

Transparent Casings and Goggles: PC’s high transparency and strength make it ideal for manufacturing various transparent casings and goggles.

The past three years were challenging for many businesses, including New Berlin Plastics: a global pandemic, a major winter storm that knocked resin producers offline, followed by an unprecedented spike in demand as the U.S. economy came roaring back from the pandemic. Now that its supply chain has begun to stabilize and these “black swan”…

The ISO 9001 certification is based on a number of quality management principles including a strong customer focus, the motivation of the employees, the process approach and continual improvement. We continually work to earn the latest ISO certifications as this helps us ensure that our customers get consistent, high quality products and services.

PC/ASA Alloy: Alloying with ASA (Acrylate-Styrene-Acrylonitrile) improves weatherability and UV resistance, suitable for applications that are exposed outdoors for long periods.

New Berlin Plastics focuses on design for manufacturability. Whether your part design is a simple housing, highly engineered component, or a cosmetic cover we will ensure your part and mold design provide you the best product possible.

UV Resistant PC: By adding UV stabilizers, the weather resistance of PC for outdoor use is enhanced, reducing discoloration and performance degradation due to prolonged UV exposure.

In conclusion, mastering polycarbonate in injection molding opens up a realm of high-performance applications due to its unique properties. By understanding the right techniques, parameters, and modifications, manufacturers and designers can harness the full potential of PC, ensuring durable, high-quality, and versatile products in a wide range of industries.

The ISO 9001 certification is based on a number of quality management principles including a strong customer focus, the motivation of the employees, the process approach and continual improvement. We continually work to earn the latest ISO certifications as this helps us ensure that our customers get consistent, high quality products and services.

Casings for Electrical Products: PC is also widely used in manufacturing casings for electrical products, such as electric meter housings. The choice of PC is mainly due to its flame-retardant properties, weather resistance, and high strength and toughness, ensuring the safety and durability of electrical products.

ISO 13485 is a quality management standard that is designed specifically for the manufacturing of medical devices. The standard is based on ISO 9001 but contains additional requirements that relate specifically to manufacturing, installing and servicing medical devices.

Here at New Berlin Plastics, we’re obsessed with driving variability out of our processes. It helps us improve part quality as well as reduce scrap, downtime, and labor costs while streamlining our operations. That’s why we’re starting to experiment with artificial intelligence (AI) in two areas. Here’s a closer look at the benefits we’re seeing…

These parameters should be adjusted and optimized according to actual machine conditions, material characteristics, and product design requirements. Correct injection molding parameters are essential for ensuring product quality and production efficiency.

Mold Flow Analysis is the science of simulating a resin’s flow into a mold and the conditions that may arise during production. This predictive process can uncover part and mold design issues and allow corrective action before mold production begins

Our tightly controlled scientific injection molding practices raise our services to the highest level of precision and allow us to create parts, simple or complex, in a repeatable and dependable way.

Now that we’re one month into 2024, many industry experts, economists, and strongly opinionated people are sharing their thoughts regarding what lies ahead throughout the year. We thought we would share our own thoughts based on what we’re seeing in our market space as well as macroeconomically. Labor The labor market continues to perform strongly.…

PC/PBT or PC/PET Alloy: By blending with PBT (Polybutylene Terephthalate) or PET (Polyethylene Terephthalate), chemical resistance and impact resistance are enhanced, often used for products requiring chemical corrosion resistance and high impact strength.

These applications demonstrate the widespread use of PC in modern industry and everyday life. Its features, such as high transparency, strength, and flame retardancy, play an important role in many fields.

Flame Retardant PC: The addition of flame retardants improves PC’s flame retardant properties. Unmodified, PC has a V2 flame retardant rating, insufficient for many products. With added flame retardants, it can reach a V0 rating. Flame retardants can be halogenated or non-halogenated.

Glass Fiber Reinforced PC: Reinforcing PC with glass fibers enhances its mechanical strength and dimensional stability, making it more suitable for applications requiring high strength and rigidity.

Optical Discs: Optical discs, such as CDs and DVDs, are typically made of PC material, benefiting from its excellent optical properties and processability.

PC/ABS Alloy: Mixing PC with ABS (Acrylonitrile Butadiene Styrene) combines the high strength and heat resistance of PC with the ease of processing and surface smoothness of ABS, along with stress crack resistance. This is widely used in automotive parts, electronic device casings, and more.

As medical device manufacturers continue to diversify their supply base to protect against supply chain challenges, New Berlin Plastics has expanded its reach into the medical device industry. To accommodate these medical manufacturers’ needs, NBP is now ISO 13485 certified, meeting international quality standards for medical device companies. While NBP continues to diversify its customer…

Mission: To understand the necessary qualities that create success for our stakeholders; boldly deploy new ideas and increase our effectiveness to provide value.

Carbon Fiber Reinforced PC: Incorporating carbon fibers improves the material’s strength and thermal stability, suitable for lightweight and high-performance applications in aerospace and automotive industries.

The ISO 9001 certification is based on a number of quality management principles including a strong customer focus, the motivation of the employees, the process approach and continual improvement. We continually work to earn the latest ISO certifications as this helps us ensure that our customers get consistent, high quality products and services.

Not long ago, there were limited options for making plastic parts that have complex geometries. A common method was CNC machining, which can be expensive and slow. Plastic injection molding is a much faster and cost-effective way to make parts, but those with intricate designs can cause quality and processing challenges. However, New Berlin Plastics…