Our Capabilities

What we offer.

Services

FPE engineering solutions are fully integrated - from design and engineering, prototype and validation through process development, to full steady-state production, we can provide your business the knowledge and means to complete your project. A fully equipped laboratory offers a wide range of physical and environmental testing capabilities. Our eight manufacturing locations have plastic injection molding capacity from 40T to 3000T and are able to support both low and high volume production runs. Extensive secondary operations provide a multitude of finishing for decorative appearances.

Molding Capabilities

As a key core process at FPE, we offer press capacity ranging from 25T through 3000T, insert and overmolding. We process most engineered and commodity based resins and with our focused tool standards we are able to provide quick tool changes and less scrap at start-up, resulting in productive molding runs and more available productive uptime.


All tooling is built by FPE approved tool suppliers who know our expectations and have demonstrated performance. Any tool transfers that are required between FPE plants can be achieved with ease due to our company wide standardization. Our quick-tool change model provides an 11 minute period from the time of the last hit of one part to the production qualification of the next. Decorative Injection Molding Tooling can be of traditional P-20 Steel or Aluminum depending on the customer preference and the economics of the project.

We have continuously improved our processes so we can offer more products with consistent quality at a competitive price:

  • Engineered and Commodity Based Resins
  • Dedicated Worldwide Tool suppliers to FPE Standards
  • Quick Change Molds-Optimize Uptime
  • Improved Cycle Time Utilizing Aluminum Molds
  • Mold-In Color or Pre-Color at Press
  • Insert Molding and Overmolding
Decorative Metal Stamping

Our Synchronous Transfer Press Line offers our customers decorative or functional type parts in either aluminum or steel with blank size capability up to 17"x12"x0.030". With our unique in-line finishing operations we are able to provide various decorative appearances such as brush, lathe or bright with a final acrylic powder top coat for surface protection.

In addition to multiple surface finishes, FPE can offer 1,2 or 3 color pad printing for decoration enhancement as well as decorative emblems and trim. Finished parts can be prepared for shipment in bulk, kit, or unitized packaging depending on the customer requirements.

Decorative Finishings

Decorative Finishing is a key core process at FPE. We offer 1K or 2K painting that may cover the entire part or masked for selective locations. Color pad printing in 1, 2 or 3 colors is also available for final decorating requirements.


 

Chrome Plastic Plating

As a key core process at FPE, we offer chrome plating on plastic parts in either bright or satin finishes. With our automated process and large plating tanks we plate parts for some of the largest applications in North America, including Class 3 and larger Truck Grilles. Plating is typically done on ABS and PC+ABS resins as directed by the client and their performance requirements.

We also utilize an Electroless Copper Plating Process to maximize adhesion and provide superior performance. Additionally, our Auxiliary Anode Technology provides consistent plate coverage for surfaces with challenging part geometry. Secondary finishing operations can be performed such as heat staking and sonic welding, as well as decorating with emblems and trim. Our complete laboratory provides all necessary testing for in-process and finished parts.
Testing includes:

  • Cass Testing/Salt Spray
  • S.T.E.P. Tester
  • Electronic Thickness Testing
  • Thermal Cycling
  • Atomic Absorption
  • Pull Testing
  • C.S.A. Testing
  • Waste Effluent Testing

Assembly

FPE has developed a great reputation based on many years of assembly experience; whether its a single fastener, several plastic sub-components welded together, a highly visible lens made of polycarbonate or clean room assembled and packaged. Our SPC, lot traceability and bar code capabilities offer our customers the knowledge and confidence that the products they receive have been assembled with the greatest of care and to precise dimensional and performance requirements. With FPE manufacturing flexibility we can process parts of both high and low volume production runs.

Joining of components can be accomplished with RF, ultrasonic welding or heat staking, depending on the needs of the customer. Components such as metal threaded inserts can be vibration inserted to provide for fastener joining.

Finally, several methods of packaging are available such as sterile or reusable packaging. FPE can lead or support the development of your packaging needs.

In utilizing value stream analysis, lean manufacturing and Total Quality Management, FPE is able to provide the optimum assembly process for the application. Whether a simple manual assembly or a highly automated, multi-assembly process, FPE will provide our customer a quality product at a value driven price. For final packaging, we can provide bulk pack, kit or unitized packaging using returnable, expendable or shrink wrap construction.

Program Management

FPE Program Management consistently provides best-in-class engineering and design capability throughout the manufacturing process, from concept and design, to processing and workplace layout. We utilize a Strict 5-Phase APQP discipline with supporting DFMEA/PFMEA and other tools to ensure a successful program execution.




 


Research & Design Capabilities

FPE design staffs a fully experienced and knowledgeable team of industrial, product and graphic designers. To learn more about FPE design, click here

Voice of Customer

At FPE, we believe that pertinent information regarding your specific customer base will go a long way in determining your market viability.

In order to accomplish this, we mock up a prototype of your product and present it to a sample subset customer base in effort to gain valuable feedback on functionality, design and user friendliness. Our process involves the following:

  • Interview Guide
  • Potential User End
  • Customer Matrix
  • Different Environments
  • Solutions you, our client, has seen
  • Communication involving voice of customer, and information on actual product needs

Concept Development

The initial concept may come from a napkin sketch that you have designed, or perhaps a fully working prototype that you want improved. Wherever you are in the design phase, we will research competitive products and do a thorough market analysis that examines any required technology and any bounding constraints.

We work with our clients to convey ideas through rough sketches and quick CAD models. From there, we narrow down the top ideas and start to build working prototypes. Working prototypes can be either:

  • Non-Functional (only look and feel)
  • Functional (working parts, but do not include ergonomics)

At this point, we bring in focus groups to refine the design according to our clients project criteria. Our clients benefit from being completely involved in the entire R & D process and can interject at any point in the process. Once a design has been agreed upon, it will advance to the technical development stage where size, weight, performance, functionality, reliability and durability are put to the test. It will also pass through several protocols that involve specifications, tooling development, component manufacturing, or design for assembly & manufacturing.

Industrial Design

Our design process combines creative thinking with proven principles to bring about the best possible outcome. Our Industrial design team works to ensure that each product is user-friendly and intuitive. They also confirm that the styling is aesthetically pleasing and end-user interaction produces a positive experience.

Prototyping

With our in-house 3D print process capabilities (Dimension 1200 3D Printer and soft tooling), EGI can design tangible prototypes in less than 24 hours. Our express prototyping allows for quick testing of a real working sample of your idea. There is no need to submit multiple quotes or wait several weeks for delivery. Prototyping parts and products is part of our valued and authentic partnership, and therefore our investment to you.

Creation of DHF

The creation of a Design History File includes any and all prints, CAD drawings, risk assessments, as well as Design Failure Modes Effect Analysis (DFMEA) and Process Failure Modes Effect Analysis (PFMEA). The DHF serves in assisting the writing, testing and report of the verification/validation plan and seeking FDA status.

Root Cause Analysis

This phase of R & D identifies problems and works to ensure that any issue is resolved before going into production. We ask the questions; why, how, where did it fail? How do we address the problem and work to resolve it? What good business practices can we utilize to improve accuracy and decrease failure rate?

Design for Manufacturing

In designing a product for manufacturing, many things need to be considered that address the products "readiness" for manufacturing. These include:
  • What is the efficiency and productivity of the product?
  • How can we make it with least amount of fasteners, etc?
  • Is it moldable? If so, how do we speed up mold flow analysis?
  • Is the design a repeatable, simple manufacturing process?

Light Weighting

In light weighting, we work to take an existing product and reduce its size and weight. Light weighting can be very beneficial as it lowers manufacturing/assembly time and increases efficiency. In addition, it decreases failures and reduces overall cost of that product.

Metal to Plastic Conversion

Using aluminum and stainless steel finishes we can convert metal parts to structurally engineered plastic. We offer many different textures and brushed metal finishes to maintain your products aesthetics and create the illusion of metal.