“We are immensely proud of these awards, especially Product of the Year, and grateful to the ARM membership for recognizing all the hard work that went into creating these parts,” said Todd St. Germain, Vice President of Sales at Formed Plastics.
“We are especially proud of our engineering team, who worked together with our customers to create these innovative designs, and of our production team, who were willing to go the extra mile to make sure these parts met the most exacting standards,” he added.
Formed Plastics earned Product of the Year honors for its Ball-Sanitizing Machine Housing, which also won the competition’
The ball-sanitizing machine sterilizes volleyballs and basketballs using ultraviolet curing high-intensity luminescence. Internal components include an injection-molded auger assembly connected to a stepper motor and electronic controls. As the ball moves through the machine, UV light bleaches its exterior and eliminates bacteria on all surfaces.
The machine was used by the US volleyball team at the 2012 Olympics in London.
Formed Plastics’ customer’s unique design for the award-winning machine housing utilizes the same double-wall rotationally molded part for both the upper and lower halves of the assembly. Molded features include an asymmetric hinge section at the rear and an interior ramp that guides the ball towards the auger.
“Using the same molded part for both the top and bottom sections significantly decreased tooling costs and expedited the timeline for project completion,”
The part is molded in LLDPE material with custom compounded color. The part geometry required minimal wall thickness, which helped decrease the weight of the assembly and lowered shipping costs. Colored graphics, including a bar code and a QR code, are molded in at seven different locations on the top half of the unit.
Graphic application posed a major challenge, particularly developing a method for applying the bar codes so that they would consistently scan correctly. Another challenge was applying the graphics within the allotted cycle time so as to stay in line with quoted costs. Formed Plastics also developed a complex system of cooling fixtures in order to ensure part straightness and hold critical dimensions.
Formed Plastics, Inc. has been one of the foremost leaders and innovators in the plastics industry since Thomas J. Long founded the company in 1946. Now in its 66th year, Formed Plastics remains a family-owned business located on Long Island in Carle Place, N.Y. Formed Plastics performs rotational molding, thermoforming, line-bending, 3-axis/5-axis machining, assembly and finishing.
Executive Vice President
Formed Plastics, Inc.