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

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. 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
  • 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

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

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


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

Sussex IM is driven to provide quality products to customers through lean applications. Product capabilities are analyzed to establish repeatable and reproducible processes to fulfill customer needs and expectations. We are committed to producing product to the highest standards by measuring, testing, and completing thorough inspections of product throughout the manufacturing process.

Capabilities Include:

  • Statistical Process Controls
  • CMM & Micro-Vu
  • Color Spectrometer
  • Leak & Pressure Testing
  • Force & Load Testing
  • Mechanical Metrology Instruments

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.


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.

Capabilities Include:

  • Warehousing
    • Climate Controlled
  • Domestic & International 3PL Services
  • Transportation/Distribution Coordination
  • Freight Consolidation


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