Custom blow molding produces unique, unusual and made-to-order plastic containers to exact specifications. The blow molding facility is involved in every step, from design concept to production to the finished product. They also manufacture the one-of-a-kind molds on-site by die casting machines.
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Custom blow molders can create all-new containers or modify and update existing designs in short or long runs. They offer every kind of blow molding, including stretch blow molding, injection blow molding or extrusion blow molding. A number of different thermoplastics are available, including polyethylene terephthalate (PET), the most common, as well as high and low density polycarbonate, polypropylene, polyvinyl chloride, Barex, butadiene styrene, polystyrene, polyamide, polysulfone and acetal. Additives that give the plastic pearl or metallic finishes as well as many different colors are often added to the thermoplastic resin when injection molding the plastic preform. While containers like cases, tanks, jars and bottles are the most popular blow molded products, toys, decoys, sports water bottles and sports equipment among others are manufactured by this process. The containers hold food and beverage liquids, including cooking oil, water, milk, juices, carbonated sodas, liquor, beer, concentrates and peanut butter. They also contain pesticides and herbicides, household and industrial chemicals and automotive oils.
The custom blow molding process starts with creating the part's design. It is made by 2D or 3D CAD drawings or to-scale SLA (stereolithography) models. The preform, called a parisan, is usually injection molded from loose plastic resin pellets into a hollow test tube shape. The parisan is then transferred to a blow molding machine, where it is softened. A metal ram forces its way through the preform's middle until it reaches the proper container height. The combination of compressed air and pressure forces the preform to balloon out and take the shape of the mold cavity. It then cures and cools, and is ejected out of the mold. Custom blow molded products tend to have more complex and difficult to produce shapes. For example, many are double walled or have irregular parting lines and can weigh anywhere from a few grams to 10 pounds. A unique, unusual container increases shelf and visual appeal, as well as provide added identity to a brand name. They are also made when a product's walls need to be stronger and tougher than normal to withstand rough forces, and durable walls that can handle abnormal amounts of stress without cracking. These specifications tend to cost more than standard one color or clear shapes, but the end product is unique, recognizable and highly functional.
