R&D Plastics Pioneers Semi‑Smart Automation in Oregon

R&D Plastics, a custom injection molder located in Hillsboro, Oregon, exemplifies the evolving automation landscape that North American molders are embracing. Since its founding in 1996, the company has transformed from a traditional demolding operation into a high‑volume, high‑flexibility facility that pairs multiple robot types for insert feeding, orientation, and placement.

Built on a 28,000‑square‑foot campus that houses 60 skilled employees and 19 presses ranging from 40 to 720 tons, R&D Plastics is approaching record sales of $8 million. The firm’s owner, CEO Rod Roth, and COO Sal Gonzalez have cultivated a culture of continuous improvement, with a strong emphasis on in‑house tooling and process innovation.

Evolving Automation

“We are a medium‑size molding company with the staff and tools of a much larger company,” says Ron Knowlton, vice president of business development. R&D Plastics offers in‑house engineering, elastomeric molding, overmolding, insert molding, structural foam, and more. While the majority of its business remains “mold‑and‑ship,” the company is expanding its secondary operations—sonic welding, hot stamping, digital printing, assembly, adhesive bonding, and fastener insertion—to meet growing customer demand.

Custom molding demands rapid change‑over; R&D Plastics routinely switches between eight molds in 24 hours while maintaining a 98 % good‑parts yield and 80 % capacity utilization. “Everything we do changes on a weekly basis,” notes Don Altorfer, maintenance manager and automation engineer.

Automation has become essential to keep pace. Most presses now feature servo robots—some cells have two—alongside automated insert feeders and conveyors. Starting in 2015, the company began purchasing Wittmann Battenfeld robots, adding five units—including two W818, two W843Pro, and a dual‑arm W818S—to its arsenal. Matthew Barnett, general manager, anticipates further acquisitions: “We’ve been very impressed with their service and support. They’re one of the best service‑oriented companies we’ve worked with.”

Altorfer recently attended a three‑day intensive training program at Wittmann’s West Coast Tech Center in Placentia, California, and returned to train his own staff. Wittmann’s West Coast Regional Manager, Jason Cornell, visits the plant every few months for advanced training and demonstrations of new features. R&D Plastics also purchased its first Wittmann Battenfeld injection press, complementing its existing Toshiba, Sumitomo (SHI), and Demag machines.

The flexibility of Wittmann robots—pre‑drilled and tapped every 5 in. along the traverse beam—facilitates rapid adjustments, making them a perfect fit for a custom mold environment.

“Today, it’s less about putting parts in a box and more about what I call ‘semi‑smart’ automation,” explains Barnett. An illustrative example is an insert‑molding cell where a vibratory feeder (built in‑house) delivers metal inserts to a conveyor. A high‑speed SCARA robot then positions the inserts precisely for a Wittmann linear robot to place them into the mold and demold the finished part.

Another example involves hard/soft overmolding cells that place two presses side by side—one for a rigid substrate, one for TPE or TPU overmolding—using a robot to transfer components between the two.

R&D Plastics’ do‑it‑yourself culture is evident in its in‑house CNC sonic welder—originally designed by founder Merrill Roth—and its custom end‑of‑arm tooling (EOAT). One EOAT tool flexes living hinges directly out of the mold, eliminating a manual step. The tool was 3D‑printed on a Raise3D Technologies dual‑extruder Pro2 printer, underscoring the company’s commitment to rapid prototyping.

Although secondary operations account for only 10 % of current revenue, the company is exploring cobots for sonic welding and other value‑added tasks. “We’re starting to look at cobots for jobs like sonic welding,” says Barnett.

“Automation also boosts employee morale and attracts talent,” says Barnett. “By automating routine tasks, we free our workforce to focus on inspection, packing, and continuous improvement—roles that are more engaging and career‑building. That ‘cool’ factor is especially appealing to younger workers who want to learn about automation that will serve them throughout their careers.”

Data Automation Grows, Too

Modern molders recognize that automating real‑time data flow is as critical as automating physical processes. R&D Plastics’ ERP system, IQMS, delivers instant visibility into mold‑floor activities, value‑added operations, mold and machine adjustments, and preventive maintenance schedules.

The company’s recent acquisition of a Wittmann Battenfeld SmartPower 300 servohydraulic injection press—part of the “smart work cell” portfolio—further enhances digital integration. The system stores and retrieves job setups for the molding machine, robot, hopper loader, additive feeder, and mold‑temperature control unit (TCU). Wittmann’s 4.0 platform promises to accelerate job change‑over and reduce setup times, supporting the company’s high‑volume, high‑flexibility strategy.

Through these initiatives, R&D Plastics demonstrates that a medium‑sized molder can leverage semi‑smart automation and advanced data integration to drive productivity, quality, and workforce development.

 

 

“Today, it’s less about putting parts in a box and more about what I call ‘semi‑smart’ automation,” says R&D Plastics’ general manager, Matthew Barnett.