Global Injection Molding //
Flexible, Scalable, Cost-Effective
- Domestic & International Manufacturing Options
- Tariff Mitigation Experts
- Engineering & Design Support Tailored to Your Needs
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Plastic Injection Molding // Designed Around You
Cost-Effective Solutions – from Prototype to Mid-Volume Production
Options For All Your Plastic Injection Molding Needs
Do you need a partner who can help you streamline new product development while also maintaining control over quality and cost? Fathom offers a scalable, flexible and expert-driven global plastic injection molding solution that can help you achieve your product launch and production goals.
Fathom is more than a parts supplier. We’re an extension of your team, providing technical guidance and operational excellence for your custom injection molding projects every step of the way.
Flexible Injection Molding Solutions
We support a wide range of customer needs – from prototyping through mid-volume production – using a combination of advanced manufacturing technologies, a global network of partners and deep tooling and molding expertise. Depending upon your requirements and budget, we can produce your parts domestically, via our international partners or using a hybrid approach.
Our international manufacturing network is designed to respond quickly to supply chain disruptions, changes in tariff policies and other geopolitical shifts – while helping you manage your injection molding costs.
We also offer a wide range of additive manufacturing solutions. Do you need help deciding if injection molding or 3D printing is right for your project? This detailed comparison can help.
Overseas
ICOMold by Fathom helps you multiply the effectiveness of your supply chain by providing you with a low-cost, high-quality overseas source for injection molding. You also get high-touch, personalized service from our knowledgeable U.S. engineers, who will also manage your project from prototype to production parts.
U.S. Based
Fathom’s McHenry, IL facility can help you with your U.S. injection molding needs. It utilizes state-of-the-art mold-making technologies to provide you with high-quality plastic injection mold design, precision mold making and close-tolerance injection molding for your projects.
Hybrid
With this option, we build more robust export tooling overseas and then ship it to the U.S. for part production. It’s ideal for companies that need to scale up part production and want to reshore their parts to do so. This combination of domestic and international plastic injection molding solutions enables you to compare them side-by-side to determine the best fit for each of your projects.
Comparing Your Options
Each option offers its own advantages and considerations, and one may work better than the other for different projects or even lifecycle stages. Fathom’s experts can work with you to determine the best route for your project.
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Dive Deeper
Optimizing for cost, quality, or production speed? Or looking for a specific material or feature for your parts? Read more on these topics to navigate the complexities of injection molding.
Real Customers.
Real Results.
“They are on the leading edge of technology in reducing lead time and cost by utilizing not only the latest technology of equipment available to them, but also in constantly reviewing their internal procedures to reduce time, reduce manufacturing costs and improve the quality of the tools being delivered to the customer.”
Dieter Lay, Arrow Development Group, LLC
Injection Molding Resources
Design & Engineering Support //
You’re in Good Hands
At Fathom, we take a human-first approach to design and engineering support. Our quotes may begin with an algorithm. But they don’t end there. Each quote includes a basic DFM, which will alert you to any potential design issues that need to be addressed.
When you award us a project, you’ll be assigned a project engineer, who will guide you through a deeper analysis of your part, tooling, process and material selection for best results. This deeper dive into your part design can help us move your part into production faster and prevent costly tool changes later.
Your project engineer will also manage the process from prototyping through mid-volume production, streamlining decision-making and keeping your project moving quickly and smoothly.
This tailored, white-glove approach is key to the success of your project – and the foundation of a long-term relationship with you.
Global Sourcing Made Simple
Fathom offers a flexible global sourcing solution designed to help you navigate your complex supply chains with greater clarity, control and cost efficiency. It includes:
- Tariff engineering and HTS classification expertise to optimize duties
- End-to-end logistics management
- DDP: Fathom is the shipper of record – which means you can take advantage of our volume discounts
- Seamless transitions from prototyping to full production
- Domestic, international, and hybrid tooling options
- U.S.-based account management and compliance oversight
This solution is especially relevant for industries like aerospace, robotics, semiconductors and medical devices, where tariff volatility and speed-to-market pressures can threaten your project’s success.
A Comprehensive Menu
of Services & Capabilities
Mold Making
Fathom offers a range of mold-making options for all of your custom injection molding needs.
Rapid Tooling // Need tooling fast? Our rapid tooling service, available via ICOMold by Fathom, produces steel tooling quickly, with delivery of sample parts in as little as 15 days. Not aluminum tooling, which has a limited life, but hardened steel tooling that is perfect for bridge and low-volume production of parts. Learn More About Rapid Tooling »
Prototype Tooling // We’ll work closely with you to define your requirements, so we can design tooling to meet your prototyping needs. Some molders build inexpensive aluminum tools for their customers’ prototype parts. We don’t believe that’s the right approach. Aluminum tools don’t hold up well and tend to get damaged easily. Also, customers often want to push them into production, far beyond what they were designed to do. That can lead to part quality problems and excessive tool wear.
We build all our U.S. and overseas tools using hardened steel. That enables us to easily move your parts from prototyping and sampling into production. It also enables us to deliver the consistent part quality you expect. ICOMold by Fathom can produce prototype tools and first samples from it in only 4 weeks.
Production Tools // We have decades of experience that help us to design the most efficient tool configuration for the geometry of your parts and the quantity you need us to produce. We also have deep expertise in designing gating and cooling systems for plastic injection molding. That helps ensure that your tools will work well and your parts will be defect-free.
Specialty Molding
Multi-Cavity Molding // We can mold multiple parts in a single tool, depending on their size. This is especially valuable if you need a lot of small parts produced quickly.
Family Molds // A special type of multi-cavity tool that enables you to produce several types of similar parts (such as right and left sides or the top and bottom of a product) using a single tool. Learn More »
Insert Molding // A metal part, such as a threaded component that will accept a screw, is placed into the tool. Plastic is then molded around it. In some cases, inserts are “hot staked” into the parts after they are molded. Inserts are often used in parts that will become part of a larger assembly. Learn More »
Overmolding // A part is first molded using rigid plastic. A softer material is then molded over the top of it so that the finished part is easier and more comfortable to hold. Overmolding is done in a single tool using an automated two-step bi-molding process. It’s a complex process that requires a team of experienced injection molding technicians to get it right. Learn More »
Two-Shot Molding // We build bi-injection rotary tools that enable two-shot molding – a process where two materials are molded together in a single cycle.
MUD Molding // In a master unit die (MUD) tool, interchangeable tools sit in a frame and can be swapped in a matter of minutes. It can be used to produce multiple variations of customized parts. Learn More »
Materials
Fathom’s U.S. plastic injection molding operation has experience with hundreds of types of materials. We also have deep knowledge of how to process them effectively. Most customer projects use these classes of materials:
- Polypropylene
- Polycarbonate
- ABS
- Engineering-grade thermoplastics
- PEEK
- Glass-filled nylon
- Polyoxymethylene (Delrin)
- Nylon (reinforced and unreinforced)
ICOMold by Fathom offers over 200 plastic injection molding materials including:
- Crystalline plastics
- Amorphous plastics
- Imidized plastics
- Polyethylene (PE)
- Polypropylene (PP)
- Acrylonitrile Butadiene Styrene (ABS)
- Polyoxymethylene (POM)
- Polystyrene (PS)
Industries We Serve
- Medical
- Pharmaceuticals
- Telecommunications
- Industrial
- Automotive & Transportation
- Consumer Electronics
- Consumer Products
- Appliances
- Sporting Goods
- Energy
Why Choose Fathom for Injection Molding?
Fathom brings a wealth of knowledge and expertise to tool design and production.
We’ve been helping customers solve their tooling and plastic injection molding challenges for decades. We’re experienced problem-solvers. We’ll work closely with you to develop the most cost-effective and efficient solutions for your needs.
Domestic Injection Molding Advantages // We do all our tool building in-house, enabling us to quickly respond to customer needs and fix production issues quickly. Summit by Fathom in McHenry, IL uses state-of-the-art machine tooling and automation to produce high-quality tools at a reasonable cost. We can also use Fathom’s Hartland, WI facility to 3D print steel cores with conformal cooling channels for our more complex builds for U.S. customers.
Because we also do plastic injection molding in the same facility, tool qualification is greatly simplified. We also do tool repairs in-house, minimizing downtime and helping to keep your parts in production.
Overseas Injection Molding Advantages // If you’re developing a new product and need a more affordable source for tooling and limited-run production, ICOMold by Fathom is an excellent fit. It provides U.S.-based engineering/design support and project management with overseas tooling and part production, enabling you to manage your new product development costs effectively.
With our extensive expertise in overseas supply chains and tariff mitigation, we can help you simplify sourcing and reduce risk for your critical parts. We can also provide you with a fully loaded cost comparison of U.S. vs. overseas injection molding costs, so you can make a well-informed sourcing decision. We’re an agile source for plastic injection molding services for uncertain times.
