Secondary Processes
Do you need to improve the appearance, durability, or functionality of your injection molded parts? Do you want to simplify your supply chain and get production-ready parts faster? If so, Fathom’s comprehensive injection molding services and secondary processes may be the solution your projects need.
Secondary processes are additional manufacturing operations performed after your parts are molded to enhance their properties or prepare them for end use. Rather than coordinating with multiple vendors for these critical finishing steps, Fathom offers a full suite of secondary processes under one roof as part of our injection molding services. That can save you time, money and logistical headaches.
From surface finishes that improve aesthetics to assembly operations that deliver ready-to-use components, the range of secondary processes we offer as part of our injection molding services can add significant value to your parts while reducing your overall project timeline and complexity.
How Can Secondary Processes Improve Your Manufacturing Workflow?
Streamline Your Supply Chain // By partnering with Fathom for both injection molding services and secondary processes, you eliminate the need to coordinate with multiple vendors, reducing lead times, shipping costs, and quality control issues. Your parts move directly from molding to finishing under one quality management system.
Enhance Part Functionality // Secondary processes like heat staking or ultrasonic welding can help join components together, while pad printing or laser marking can add critical information or branding. These processes transform basic plastic injection molded parts into functional, market-ready products.
Improve Aesthetics // Surface treatments such as painting or coating can dramatically improve the appearance of your parts, helping your products stand out in the marketplace and meet customer expectations for quality and design.
Ensure Quality & Consistency // Having the same team handle both injection molding services and secondary processes ensures consistent quality standards throughout production. Our experienced technicians understand how each process affects your parts and can make adjustments to optimize your results.
Reduce Time to Market // Eliminating the need to ship parts between vendors for different processes can significantly reduce your overall production timeline, helping you move your products to market faster. We handle everything from injection molding services to secondary processes needed to finish your parts. It’s simpler, faster and more cost-effective than finishing the parts yourself or outsourcing that work to a separate vendor.
Secondary Processes We Offer
Fathom offers a wide variety of secondary services as part of our domestic and international injection molding services:
Surface Finishing
Painting // Professional-grade painting provides color consistency, UV protection and enhanced aesthetics. Our painting capabilities include:
- Powder coating
- Spray painting
- Specialty finishes
Assembly Operations
Ultrasonic Welding // This process uses high-frequency sound waves to create molecular heat between thermoplastic materials. This causes the plastic to melt and form a bond between the parts.
Hot Plate Welding // This process uses a heated platen to melt the joining surfaces of two thermoplastic parts.
- Enables precise control of the melt temperature
- Results in excellent weld strength
- Can be used to weld large, complex parts.
Heat Pressing // Metal inserts are heated and pushed into the plastic parts.
Heat Staking // This process joins two parts by inserting the stud of one part into a hole of another part. Heat is then applied to the stud to deform it and mechanically lock the parts together.
Assembly // We can assemble parts if needed, saving you valuable time and factory space. Parts will arrive fully assembled and ready for use.
Packaging // We can produce, assemble and package your parts, if needed.
Functional Enhancements
Post-Molding Machining // After the injection molding process is completed, additional CNC machining can be performed to:
- Remove flash
- Change the shape or texture of the part
- Bring surfaces within the tolerances requested by the customer
- Prepare the part for further post-processing.
Identification & Marking
Pad Printing & Screen Printing // These processes are used to add graphics to parts. Screen printing requires a relatively flat surface. Pad printing can be done almost anywhere on the surface of a part. Pad and screen printing are often used for:
- Branding
- Labeling
- Part number identification
Labeling // We can add labels to your parts if you supply them.
NOTE: In addition to custom injection molding, Fathom offers secondary processes at Summit by Fathom, our U.S. location for injection molding, and via our international manufacturing network. Services vary by location.
Industries That Benefit from Secondary Processes
Thanks to the versatility of plastic injection molding, it’s widely used in many industries. Each of them has a specific set of finishing needs:
Automotive & Transportation // Parts that require precise assembly, durable markings and aesthetic finishes.
Medical Devices // Components that need clean welding, permanent identification and validated assembly.
Consumer Electronics // Products that require attractive finishes, secure assembly and information marking.
Industrial Equipment // Parts that need functional coatings, durable identification and reliable assembly.
Aerospace // Components that require specialized coatings, precise markings and certified assembly processes.
Consumer Products // Parts that benefit from attractive finishes, brand identification and ready-to-sell assembly
Why Choose Fathom
for Secondary Processes?
Fathom offers decades of experience in both injection molding services and secondary processes – a comprehensive solution for your manufacturing needs.
Our U.S.-based engineering team will work with you from the initial design phase to identify which secondary processes will best enhance your parts’ functionality, appearance and overall value.
By choosing Fathom for both injection molding services and secondary processes, you gain:
- Simplified Project Management // One point of contact for your entire project
- Reduced Lead Times // Elimination of shipping between vendors
- Enhanced Quality Control // Consistent standards throughout production
- Technical Expertise // Engineering support to optimize your part design for both molding and secondary processes
- Scalable Solutions // Capabilities that grow with your production needs, from prototype to full-scale manufacturing
- Space Savings // Instead of dedicating limited factory floor space to perform these secondary operations in-house, you can save it for higher-value manufacturing activities.
When it comes to custom injection molding, our approach isn’t just click-to-quote—we act as an extension of your team, providing technical guidance and operational execution at every step. Whether you need domestic production, international manufacturing or a hybrid approach, Fathom helps you make informed decisions and ensures every part meets the highest standards for performance, consistency and value.
Let’s get started on your custom injection molding project with secondary processing today!
