At Exothermic, Reaction Injection Molding Plays Well with 3D Printing

Founded in 1972, Exothermic Molding Inc. began by serving specialized markets including medical equipment, electronics, and laboratory instruments. Under the leadership of President Paul Steck, the company has evolved into a versatile manufacturing enterprise, with its recent success largely driven by embracing 3D printing technology.

The integration of 3D printing has revolutionized Exothermic Molding's operations. "The technology keeps advancing at an incredible pace," Steck notes. "What's cutting-edge today becomes entry-level tomorrow, often at half the cost with enhanced capabilities." He points to their latest large-format printer as an example, where a simple software upgrade dramatically improved both speed and resolution at minimal expense.

Breaking Traditional Manufacturing Boundaries

Customer demand has increasingly shifted toward components that defy conventional manufacturing methods. The company now regularly incorporates 3D-printed parts into their assemblies, including innovative fire-retardant materials that meet UL 94 certification standards. With each printer upgrade – they're now approaching their fourth generation – Exothermic Molding expands its capabilities and market reach.

The expansion of their build capacity from 20 to 40 inches has opened doors to new markets requiring larger components. While medical instrument housings and test equipment remain core offerings, the company now serves diverse industries with complex sub-assemblies.

Investment in People and Infrastructure

This technological evolution demanded significant investment in human capital. The company has both trained existing staff and recruited engineers with advanced CAD expertise. Taking advantage of investment tax credits, they've modernized their facility, replacing outdated equipment with more efficient solutions.

While 3D printing still produces parts requiring finishing work, Steck sees this as an opportunity. The company offers comprehensive finishing services and explores hybrid approaches, combining rapid, lower-resolution printing with precision machining to achieve superior tolerances.

"The manufacturing landscape is undergoing a complete transformation," Steck observes. "From 3D-printed injection molds to carbon-fiber composites and metal printing for jet engine components, the possibilities keep expanding. Even the military is adopting this technology to streamline their supply chains."

Operational Innovation

Exothermic Molding has streamlined operations through improved storage systems and workspace optimization. They're exploring an innovative "deployable operation" concept – similar to the store-within-a-store retail model – where they could set up manufacturing facilities within or near customer locations, eliminating the need for heavy equipment and expensive molds.

The advent of 3D printing has leveled the playing field between small and large manufacturers. "The technology has lowered barriers to entry significantly," Steck explains. "Smaller companies can now compete effectively thanks to shorter development cycles and reduced initial investment requirements. The potential to disrupt traditional distribution networks through print-on-demand services is enormous."

Looking ahead, Steck advocates for greater support from technology providers, particularly for small businesses building print farms. He emphasizes the need for material sourcing assistance and finishing expertise, suggesting that larger companies could share their R&D insights and market exposure to benefit the entire industry.