Capabilities
Complete, in-house, precise.
Design, tooling, molding, and assembly — a vertically integrated partner from concept to finished product.
Design & Engineering
Intellectual Property Solutions
The Knapp Mfg. Design team has assisted our customers in receiving (and traversing) multiple patents for their proprietary devices. We are versed in the patent process and have worked to simplify designs into robust products while documenting the innovations that can be protected by patent. Our approach to design is predicated on the manufacturability of products, ensuring our customers go from concept to production in one smooth transition.
Fluid Power & Pneumatic Testing Development
Our team specializes in fluid power and pneumatic testing. We leverage the knowledge base of our sister company Air Logic with our internal automation capabilities to produce a full solution for the assembly and testing of products. Leak, flow, and function testing can all be performed in a safe and cost efficient manner.
Components & Molds
Knapp Mfg. is a vertically integrated facility with Design, Prototyping, Tooling, and Molding capabilities in house. We use those capabilities to produce quality designs, components, and robust time-tested molds to a standard we are proud to put our name on — working in collaboration across all departments.
Mold Making
Ultra-Tight Tolerance (.0005 – .001)
Knapp Mfg. has been synonymous with precision since Fred Knapp founded the company in 1945. Our team is capable of building SPI Class 101 tools and molding parts that hold tolerances as tight as +/- .0005 of an inch. We currently run over 100,000,000 parts a year with this tolerance on critical features of customer products.
Robust Molds
The standard plastic injection molding tool produced by Knapp Mfg. is built to SPI Class 101 standards — the highest class tooling available, with fully inserted and hardened cavities and cores. We warranty these tools to run one million cycles or more.
In-House Maintenance & Repair
Even the best made SPI Class 101 tools need maintenance to live up to the one-million-plus cycle expectation. With our fully stocked and staffed tool room we maintain, modify to customer specification, or repair tooling without having to "send it out." Our tool room has modern Die-Sinker EDM capability as well as CNC machining capability.
Plastic Injection Molding
Process Control
Molded part quality is overseen by our 5-member team. Knapp offers inspection levels from 100% to .25% based on part complexity, usage, and customer needs. Hourly samples are taken for some or all jobs which require visual inspection, air flow testing, gauging, and measuring — with "Real Time" quality control monitoring for ultra-precision parts. We are ISO 9001:2015 Certified.
Acrylic to Zytel™ Resins
We run a multitude of resins ranging from acrylics to Zytel™. Warehouse storage of 20,000 ft² for colorant, additives, resins, and molded components, with a temperature range up to 670 degrees.
10 Ton to 165 Ton Capacity
Our press capabilities range from 10 tons (⅓ ounces) to 165 tons (7 ounces).
1 to 4 Hydraulic Core Pulls
For complex molds, a maximum of 4 individual hydraulically sequenced core pulls. We provide ancillary equipment for mold heating, resin drying, and blending.
Small to Large Run Capability
Knapp Mfg. molds to our customer's needs. We receive orders ranging from 5 to 1.5 million pieces and maintain a 99.5% on-time delivery. Our well-diversified customer base ranges from fluidic and pneumatic components, fluid dispensing components, and medical components to aircraft instrumentation components.
Contract Manufacturing & Custom Assembly
Light Assembly
Knapp specializes in the assembly, testing, and packaging of precision plastic injection molded components. We provide everything from custom assembled products to semi-finished and completely finished SKU-level products.
Manual, Semi-Automated & Fully Automated Assembly
Manual — using Lean manufacturing and Six Sigma practices, Knapp maintains high quality and competitive labor costs on high-mix short production runs. Semi-Automated — for higher production or more demanding mechanical forces, our automation team has designed semi-automatic machinery that improves consistency and reduces operator strain. Fully Automated — solutions increase productivity and drive down labor costs, with equipment capable of loading, inspecting, and functionally testing products in an autonomous work cell.
Incoming Inspection to System Functional Testing
Knapp incorporates its ISO 9001:2015 certified Quality Management and Control system into every aspect of its vertically integrated business model. We perform thorough incoming, in-process, and dock audits for all purchased, molded, and assembled components — checking flow rates, pressure leak decay rates, vacuum generation levels, and dilution control rates. Coupled with visual and manual inspection, we utilize custom engineered Go/No-Go fixtures and an optical vision system that detects flash, gaps, concentricity, and other deviations.
Integrated Systems
Knapp's Design and Automation Team designed, developed, and fabricated numerous semi-automated and automated production systems that integrate inspection, assembly, ultrasonic welding, dimensional checking, and leak/flow testing into one machine.
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