Mid-Atlantic Rubber Inc
Injection Molding Services
LSR, Plastic Injection & Cable Overmolding. From Prototype to Production.
Injection Molding Services
When your application requires a molded rubber or plastic component that performs consistently across thousands or millions of cycles, injection molding is the process that delivers. At Mid-Atlantic Rubber (MAR), we operate a full in-house injection molding department capable of producing parts in Liquid Silicone Rubber (LSR), thermoplastics, and overmolded cable assemblies.
Injection molding gives you repeatable precision, material consistency, and the ability to produce complex geometries that would be difficult or impossible to achieve with cutting or fabrication alone. And because everything runs under one roof at our Fredericksburg, VA facility, we control quality from raw material to finished part.
Our Injection Molding Capabilities
MAR’s injection molding department supports three distinct process types, each suited to different materials and applications:
Liquid Silicone Rubber (LSR)
- Medical-grade seals, gaskets, and flexible components that require biocompatibility, extreme temperature resistance, and long-term durability.
- Temperature range: -65°F to 450°F. Excellent compression set resistance. Hypoallergenic and FDA-compliant options available.
Plastic Injection Molding
- Housings, enclosures, brackets, connectors, and functional components in engineering-grade thermoplastics.
- Materials include ABS, nylon, polycarbonate, PEEK, POM, and more. Tight tolerances and high repeatability.
Overmold Cable Assemblies
- Cable assemblies with molded strain reliefs, connectors, and environmental seals built directly onto the cable.
- Combines injection molding with cable assembly to create sealed, ruggedized connections for military, aerospace, and medical applications.
Why Injection Molding?
Injection molding is the go-to process when you need high volumes of identical parts with tight tolerances and consistent material properties. Here’s why it’s often the best approach:
Repeatability
Complex Geometry
Material Performance
Production Speed
Low Per-Unit Cost
Integrated Assemblies
Liquid Silicone Rubber (LSR) Molding
LSR is a two-part platinum-cured silicone that’s injected into a heated mold and cured in seconds. The result is a flexible, durable part with exceptional performance characteristics that make it ideal for demanding applications.
Key properties of LSR parts:
Temperature resistance
Maintains flexibility and seal integrity from -65°F to 450°F.
Biocompatibility
Chemical resistance
Compression set resistance
Optical clarity
Low toxicity
Industries We Serve
MAR’s injection molding services support manufacturers across industries where precision, material performance, and reliability are essential:
- Military & Defense
- Aerospace
- Medical Devices & Equipment
- Automotive & Transportation
- Industrial Equipment & Controls
- Consumer Electronics
- Telecommunications
- Food & Beverage Processing
Case Study
Consolidating a Multi-Vendor Cable Assembly Program for a Medical Device Manufacturer
Client Name
Veridian Medical Technologies
Industry
Medical Devices
Location
Charlottesville, VA
The Challenge
Veridian Medical Technologies manufactures portable patient monitoring systems used in hospitals and field clinics across the eastern United States. Each monitoring unit requires three custom cable assemblies that connect external sensors to the main device housing. These assemblies need overmolded connectors with integrated strain reliefs and environmental seals rated to IP67.
Veridian had been managing this program across three separate vendors: one for the cable harness, one for the molded connector housings, and a third for final assembly and testing. The multi-vendor arrangement created persistent headaches. Lead times stretched to 10 to 12 weeks. Communication gaps between suppliers led to dimensional mismatches that caused roughly 8% of assemblies to fail incoming inspection. And when a design change was needed, coordinating across three vendors could take a month before updated parts were in hand.
Veridian’s supply chain director was looking for a single partner who could handle the entire cable assembly process from raw cable to finished, overmolded, tested assemblies.
The MAR Solution
Veridian contacted MAR after learning about our combined injection molding and cable assembly capabilities. After reviewing the assembly drawings and material requirements, our team proposed a consolidated program:
Cable assembly
Overmolding
Environmental sealing
Testing
We built the overmold tooling in-house and delivered first article samples within three weeks. Veridian’s engineering team approved the samples after a single round of testing with no modifications required.
The Results
Within the first six months of production, Veridian’s cable assembly program saw significant improvements:
8% to 0.3%
10–12 Weeks to 4
3 Vendors to 1
The integrated overmold design also reduced the overall component count per assembly from 14 pieces to 8, which lowered Veridian’s bill of materials cost by roughly 22%. Fewer components meant fewer failure points in the field, which contributed to a measurable drop in warranty claims on their monitoring units.
“We spent two years managing three vendors for one cable assembly. MAR took over the entire program and delivered better quality in half the time. The overmolded design is cleaner, more reliable, and easier for our production team to work with. It’s exactly what we needed.”
Dana Whitfield,
our process
Our Process: From Concept to Molded Parts
Here’s how a typical injection molding project works with MAR:
Design Review & Material Selection
Tooling & Prototyping
First Article & Qualification
Production & Delivery
Ready to Solve Your Gasket Challenge?
Send us your drawing or specs and get a no-obligation quote.