Rion and its subsidiary Plastokit don’t stop at just injection molding. They provide a wide range of supplemental processing services that offer a comprehensive solution to customer requirements. These include metal processing, ultrasonic welding, insertions, pad printing, laser marking, milling and machining, and even electrical circuit assembly.

Efficient and Fast Supplemental Processing

From the early product design phase, engineering teams work to optimize production. Nadav Zamir, Rion’s Operations Manager, explains: “We pay attention to the customer’s requirements at the early stage of mold design. Sometimes, we can eliminate the need for supplemental processing through better mold design, which takes into account the final product and allows additional processes on top of injection molding”.

However, there are times when supplemental processing is unavoidable to achieve a finished product at a high-quality level. Some of those processes are short and quick, such as cutting the sprue or drilling, while others are more complex, requiring fine-tuning and adjustments, such as ultrasonic welding. “We aim to move parts to supplemental processing immediately after injection molding, without delays caused by intermediate storage,” explains Omer Kraus, Manager of Plastokit’s factory. “The goal is to manufacture and complete the processes as quickly and continuously as possible. In recent years, we’ve also invested in automation, which streamlines and shortens supplemental processing.”

Automated Pad Printing, Laser Marking, and Insertions

An example of such efficiency is the comprehensive upgrade of the automation cell at Plastokit, which produces a test tubes tray for a company in the medical industry. Initially, the tray is injection molded and then undergoes several supplemental processes: precise embedding of insertions, pad printing of the company’s logo, and laser marking of a barcode containing a serial number. The marking is performed on multiple sides of the tray, after which a robot checks the barcode for readability.

“Our upgraded laser system is an example of improvement and efficiency. Not only have we increased output, but we’ve also added more operations that were previously performed manually, freeing employees for more important tasks,” says Omer. “Laser marking replaces labels that can wear out and peel off. It’s an environmentally-friendly process, as it eliminates the use of paper, adhesives, and solvents. Working with the medical industry is challenging since it requires compliance with strict regulations and lengthy Validation and Verification (V&V) processes. With the new system, we can respond quickly to growing market demands.”

Ultrasonic Welding of Plastic Parts

Joining plastic parts can be done in various ways – from mechanical joints such as adhesives, riveting, and screws to advanced methods like ultrasonic welding. The advantage of this method is the creation of a strong and sealed seam quickly and effectively for a wide range of polymers. The ultrasonic welding tool vibrates at a very high frequency, transmitting these oscillations to the welding area. The frictional heating generated by the vibrations melts the surface of the parts to be joined. After pressing the parts together and cooling, a strong and complete bond is formed.

At Plastokit, we use advanced welding equipment from the long-established German company Herrmann Ultraschall, which specializes in ultrasonic welding. As an example, Omer describes a milk meter installed in a milking system that monitors the amount of milk produced by the cow during the process. An insert is embedded and welded to the meter itself. The welding station allows for both narrow and wide welding, with Dimitry Gorenshtein, the engineering technologist, responsible for the appropriate setup and adjustments. Afterward, employees perform the welding process on the parts themselves.

Photo 1: Ultrasonic welding station at Plastokit

Machining – Milling, Turning, and Drilling

At Rion and Plastokit, machining processes are performed both with simple mills and CNC machining. The simpler processes include removing thick sprues or drilling holes in various parts. In such cases, portable milling tools have been built, which are moved between machines where the supplemental processing is performed. “Here too, the idea is to complete the supplemental processing as close as possible to the injection molding process. We built sets of milling tools that move between the machines, allowing employees to perform milling quickly during production,” Nadav explains.

For more complex products requiring threading or advanced milling processes, the parts are transferred to CNC machines. Rion has found a way to optimize the process by working with two working stations. While the machine works on one working station, milling multiple products, the worker unloads the finished products from the second one and arranges the next set of products. Once the CNC work is completed, those are swapped quickly, and the machine continues its work uninterrupted.

Made to Customer Specifications

Rion believes in tailoring solutions to the needs of the customer and the project. Whether improving existing processes or implementing new technologies, customers can rely on the company’s engineering teams and experts to deliver solutions that perfectly match their needs. “We always think about how to perform the processes in the most efficient way,” Nadav concludes. “We have invested in technology, automation, and expertise to ensure our customers receive not only high-quality products but also a comprehensive and cost-effective service.”