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We Manage Your Project From Start To Finish

With our dedicated teams here at Sussex IM, we ensure that your project is managed from start to finish. Our teams will assist through every step, from the design down to the logistics. We are a hands-on team that enjoys new projects and working closely with our customers throughout the delivery.

Design for manufacturing icon

Design for Manufacturing

Precision, speed, tight specifications—it all begins with design. Our engineering, tooling, automation and robotics teams provide a combined 195 years of designing, building and integrating custom solutions. The Sussex IM team becomes an extension of YOUR team – making best recommendations for molding efficiencies, part stability, and a robust manufacturing process all the way down to the assembly. We work with you to design your product to be the aesthetically pleasing performer your customers want, while being produced in the most efficient and cost-effective manner possible.

Capabilities Include:

  • Mold Flow Analysis
  • Design for Automation
  • Design for Assembly
  • Mold Design & Review
  • Material Selection
  • 3D Rapid Prototype & Models
Design for engineering


It is much easier to visualize a part when you can actually hold it in your hand. Here at Sussex IM we have a team of engineers who assist our customers in creating their ideal product.

We use 3-D printed models for the following reasons:

  • Enhanced product development
  • Faster speed to market
  • Mass customization & Design verification
  • Build custom fixtures for secondary and auxiliary equipment
Advanced manufacturing

Advanced Manufacturing

In addition to custom injection molding operations, Sussex IM uses progressive technologies to develop unique manufacturing solutions for our customers.

Capabilities Include:

  • Integrate extrusion blow-molding and insert injection molding with in-line leak testing
  • Designing four-sided robotic fixtures to deliver an in-mold-labeling process to create a cubic-shaped container with 4-sided graphics
  • Developing a flexible multi-shot insert molding work cell to produce a personal care device in nine different sizes
Manufacturing Engineering

Mfg. Engineering/Automation

Our manufacturing engineering team is an extension of our customers – we help add value to our customers product through implementing state-of-the-art technologies to reduce variability. Further, implementing automation ensures the product is made with the highest quality possible. Our engineering team designs and builds the majority of our automated systems in-house. By doing that, we have complete control over the design, build, and validation process. We can then support the equipment while it runs throughout the life cycle of the product.

Capabilities Include:

  • Sonic and vibration welding
  • Design of EOAT’s for part extraction
  • High-speed labeling and assembly systems
  • 4 and 6-axis robot programming
  • Usage of vision for robot tracking and part inspection
  • PLC/HMI/SCADA programming
Assembly Icon


Our capabilities with regard to product assembly differentiate Sussex IM from a typical custom injection molder. Our in-house team of automation engineers develops custom solutions based on the requirements and scope of your program.

Capabilities Include:

  • Manual Assembly- Sussex IM technicians and operators are trained and skilled at reliably producing completed and validated product.
  • Semi-automated Assembly- Combining automation with manual assist often provides the best scenario with regard to efficiencies and productivity.
  • Automated Assembly- Robotics, Press-side, Rotary Index, Linear Index, Continuous Motion, Cam Drive, Cylinder Driven, Manually/Auto-loaded, Jigs & Fixture.
Quality Inspection

Quality Inspection

Quality is integrated into many steps of the design-for-manufacturing process to reduce speed-to-market time and prevent downstream bottlenecks. At Sussex our quality engineers work within our engineering team to target quality processes during each phase of a product launch starting with DFM all the way to in-line part inspections.

Utilizing state-of-the-art technology including our CMM machine outfitted with the new EYE-D camera technology offers customers reduced quality time and increased precision.

Capabilities Include:

  • CMM with EYE-D Technology
  • Leak & Pressure Testing
  • Force & Load Testing
  • Mechanical Metrology Instruments
  • Resin Moisture Testing
  • Custom gauges
Returnable Packaging Logo

Returnable Packaging

Providing sustainable and cost-effective solutions to our customers is top priority at Sussex IM. We have assisted our customers in the health and hygiene, cosmetics, and other markets with the option of returnable packaging to help reduce our carbon footprint.

Logistics Icon


Sussex IM has dedicated 3PL capabilities and capacities which have been used to successfully supply logistics management to customers in the agricultural, personal care device, and food service markets. We strive to continuously improve our shipping and packaging process to eliminate excess packaging and find the most cost-effective shipping method for our customers.

Capabilities Include:

  • Climate-controlled Warehousing
  • Domestic & International Shipping Services
  • Transportation/Distribution Coordination
  • Freight Consolidation
  • Fulfillment Services
    • Distribution Centers/Retailers
    • Pack per Store
    • Amazon Seller Fulfilled/FBA (Fulfillment by Amazon)
    • Direct to Consumer (D2C) Shipments

Transfer Programs

Looking for a new custom injection molder? At Sussex IM, we pride ourselves on providing seamless transfer tooling services. With our experienced manufacturing, tooling, and technician teams we are able to diagnose the molding problems and find a solution for you. Depending on the complexity of the project, availability of raw materials and part approval/qualification speed, we can typically get your project up and running within weeks from receipt of tool and purchase order.

Tooling engineer holding a tool with a crane


Please feel free to contact us; we would love to help!