Optimizing Processes, Efficient Results

Ensure your manufacturing operation leaves nothing on the table with Formerra’s process development and optimization services. Our experts combine scientific methodologies with decades of practical experience to help customers improve manufacturing efficiency, reduce waste, and maintain consistent product quality.

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Together, We Can Unlock Your Operation’s Peak Performance

After months or years of research, design, and testing, your perfect product is ready for at-scale manufacturing and distribution. The last thing you need is tooling downtime, assembly errors, or surplus scrap to diminish the quality or profitability of your products. Formerra’s Application Development & Technical Services (ADTS) team is here to help your processes run like the well-oiled machine your product deserves. We combine material science knowledge with process engineering expertise to optimize every phase of production, whether you’re looking to revitalize existing processes or develop from the ground up. From gating issues and mold wear to capacity constraints and scrap reduction, our experienced team provides practical, hands-on support to help you achieve maximum efficiency, quality, and cost-effectiveness with minimal waste.

Collaborative, End-to-End Manufacturing Process Support

Formerra’s process development services are designed to help ensure your operation is set for success at every stage. Our team collaborates with yours to apply scientific molding principles, process validation techniques, and advanced analytical tools that optimize key processing parameters from concept to full-scale production.

How We Help

We provide a full range of process development capabilities and services to enhance operations, maximize efficiency, and address potential complications before they arise.

Scientific Molding & Process Parameter Optimization We employ practical, data-driven methodologies to fine-tune injection molding parameters, improving part consistency and reducing defects through:

• Developing and validating initial processes for new tools
• Applying scientific molding techniques to optimize pressure, speed, temperature, and other key factors
• Conducting pressure drop studies for efficient material flow in injection molding

Cycle Time & Machine Utilization Optimization Our process experts draw from decades of experience to improve speed while maintaining quality by:

• Optimizing fill, pack, and cooling phases to reduce cycle inefficiencies and speed production
• Refining extrusion speed, injection fill speed, and holding pressure to maximize output
• Minimizing downtime by determining optimal machine settings and preventing unnecessary wear

Material Processing Optimization We put our material expertise to work, enhancing performance and consistency while minimizing waste by:

• Adjusting viscosity, melt flow, and shear conditions for consistent processing part quality
• Improving melt homogeneity and extrusion stability to boost efficiency
• Optimizing cooling and pressure control to prevent defects like warpage and shrinkage

Design for Manufacturability (DFM) & Tooling Support Our knowledge of gold-standard design principles and manufacturing across applications supports improved manufacturability and process efficiency, helping you:

• Integrate DFM best practices to minimize the risk of defects and production delays
• Confirm tooling and mold design compatibility with specific process requirements
• Validate mold gate placement, cooling layouts, and ejection strategies for optimal performance

Process Validation & Data-Driven Analysis We use advanced analytical tools and data-driven insights to validate processes and enhance efficiency, including:

• Access to mold flow analysis and finite element analysis (FEA) capabilities, enabling the prediction of material behavior and optimization of processing conditions
• Relative viscosity curve analysis to fine-tune processing conditions
• Thermal imaging to improve cooling and material stability

Comprehensive Technical Expertise From the first design concept to the production line and beyond, Formerra's expert-led Application Development and Technical Services (ADTS) team is here to provide comprehensive technical support tailored to your industry and requirements.

Ready to Perfect Your Process?

Reach out to our technical support team today to learn how our process optimization services can help your operation work smarter, not harder.