Our Capabilities

• Automated trimming equipment including CNC Routers.
• CAD systems for product design, CAE and FEA simulations.
• Single-piece joint-less molded part sizes ranging from mere 0.1 meters to 4.1 meters in diagonal length.
• Complete in-house mold manufacturing and maintenance capabilities including CNC/VMC machines.
• Metal to Plastic conversion, Wood to Plastic conversion.
• A range of shapes, from simple to intricate.
• Custom colored products.
• Complete assemblies per customer specifications.
• Molding experience of a wide range of materials from Polyethylene to polyamides and polypropylenes.

• XLPE fuel tank specialists.
• In-mold polyethylene foam layers.
• Post-mold polyurethane foam filling.
• Dependable PIAT monitoring and controlling system.
• Extrusion and Pulverizing capabilities.
• In-mold inserts, labels and graphics, cut-outs, foams.
• Detailed and reliable product testing, functional conformance and validation systems in-house.
• Fully equipped and staffed material testing laboratory.
• Highly evolved Enterprise Resource Planning (ERP) systems from SAP custom-built and best suited to roto-molding needs. Our systems effectively manage customer expectations by tying in forecasts and requirements.

There are many custom rotational molding companies in the market to choose from but There is no other company that can match BDI in providing custom design and engineering solutions.

Our commitment is clear, from our dedicated Research & Development department to our engineering resources focused on:

• Industrial Design
• Project Engineering
• Manufacturing Engineering
• Quality Engineering

Here is what we do for our customer-partners:

• Product Design
• Value engineering and value addition
• Material selection based on functional requirements
• Tooling Design
• Tooling manufacturing
• Product Trials
• Product Assemblies
• CNC or manual trimmings
• Validation and Conformance to spec
• Short lead time developments
• Reliable just-in-time (JIT) deliveries with 100% consistency
• Tooling storage, maintenance and upkeep
• Inventory Planning
• Inventory Management
• Quality documents
• Revision control
• Type Approval Certification for regulation from ARAI, ICAT, etc.

A fully staffed, 30+ members Engineering Department totaling over 125 years of engineering experience.
Our fully equipped Research and Development Team, also unique to the industry, has delivered critical products to the marketplace to meet environmental and other regulations.
We love talking to startups and anyone with an idea for a product. We’ve helped many of them go from dreamer to product manufacturer! From online thesis writing design, to development documentation to final specifications, even potential product partnerships. We can help with the entire process and help you with a go-to-market strategy!
Working with our engineering staff will give you the assurance that your projects are being optimized for efficient manufacturability while staying true to your original intent.

BDI will

• Advise you on the suitability of your design for its intended purpose.
• Assist you in creating appropriate specifications.
• Verify critical specifications using a fully equipped testing lab.
• Help identify, source and integrate components into your products, by drawing on an expansive knowledge base derived from the market segments we serve.
• Our relationships with key vendors and our engineering capabilities allow us to assist you in selecting the appropriate component for your application.

Our technical teams effectively integrate with our customer’s engineering and marketing groups to provide assistance with early product concept creation. Following the development of a selected concept, we support the creation of a production ready design.

This phase includes

• Concept sketches in electronic format.
• Feasibility models utilizing Advanced Surfacing and Style feature capabilities in SolidWorks.
• Early expert evaluation of manufacturability and concept viability.
• Product feasibility estimates.
• Assistance with development of 3D models.
• Firm production tool pricing and part pricing.
• Full part production package including PFMEA, control charts, and capability plans

At BDI, we utilize our own comprehensive Production Part Approval Process (PPAP) based upon our intimate understanding of the process and developed in collaboration with our customers to ensure quality parts by design.

Our robust 19-stage PPAP ensures our new developments are first time right, every time right. Our PPAP includes the following documents leading up to the Part Submission Warrant (PSW) with our customer.

• Initial Sample Inspection Reports (ISIR)
• Control charts
• DFMEA
• PFD
• PFMEA
• Capability studies
• RoHS and REACH compliance

Highly evolved Enterprise Resource Planning (ERP) systems from SAP custom-built and best suited to roto-molding needs. Our systems effectively manage customer expectations by tying in forecasts and requirements.

• Polyethylene
  • LLDPE
  • LMDPE
  • HDPE
  • XLPE (Cross linked PE)
• Polypropylene (PP)
• Polyamide (Nylon)
• Polybutene-1
• Polycarbonates
• PVC (Plastisol)
• Flame Retardant materials
• Anti-Static materials
• Electrically Conductive plastics

Material Level Testing

• Computerised Twin-screw UTM Nx (for tensile, flexural, etc.)
• Heat Deflection Temperature
• Vicat Softening Point
• SCR tester
• IR Temperature gun
• MFI tester
• Humidity Chamber
• IZOD Impact tester
• Hardness tester shore A
• Hardness tester shore D
• Gel Content testing (for XLPE)
• Carbon content testing
• Hot air oven (Laboratory)

Product level testing:

• TempLogger (PIAT)
• Drop test
• Pendulum Impact test
• Overturn test
• Hydraulic Test
• Mechanical Strength test
• Insert retention (pull-out)
• Ultrasonic wall thickness tester (non-destructive)
• Boro-scope camera (for internal surface inspection)
• Filler cap pull-off test
• Burst test*
• Pressure drop testing
• Weight test
• Leakage testing
• Static charge eliminator
• Barcode tracking
• Full dimensional inspection*