What Stelray Plastic Products does

Stelray Plastic Products, Inc. is a second-generation, family-owned precision plastic injection molding contract manufacturer headquartered in a ~42,000 square-foot facility (with a 5,000 SQFT expansion completed in 2023) in Ansonia, Connecticut. Founded in 1961 by Mort Saffran and currently led by his son Lawrence (Larry) Saffran as President, Stelray operates a 22- to 620-ton clamp-force press fleet across multiple shifts, an in-house tool room with master toolmakers, a Micro-Vu-equipped metrology lab, and a segregated white room for medical molding (targeting ISO Class 8 certification by year-end 2026). The company ships roughly 28 million parts per year and serves Fortune 500 OEMs across medical and dental devices, electronics and instrumentation, aerospace, automotive and defense, consumer appliance, and water and chemical filtration.

Stelray's core technical capability is end-to-end custom injection molding executed under a 'resin-to-box' model that spans engineering and Design for Manufacturing (DFM) review, rapid prototyping, custom mold build, molding, in-line post-mold operations (ultrasonic welding, pad printing, hot stamping, heat-staking, painting, plating), assembly, and retail-ready packaging. Differentiated production assets include a 620-ton Haitian press with an integrated 3-axis robot (added in 2023), 3D printed H13 tool-steel tooling with conformal cooling (launched July 2025 in partnership with U.S. toolmakers), and a fully rebuilt metrology lab (2024) using Micro-Vu VMM and CMM equipment. Quality systems are anchored by ISO 9001:2015, FDA 21 CFR 820 Medical Device Manufacturer registration, and cGMP compliance, with additional conformance to UL, ANSI, ASME, ASTM, and CE marking requirements.

The business model is project-based B2B custom manufacturing: pricing is quote-driven, influenced by part complexity, resin selection, cavitation, and production volume, and structured as multi-year tooling and production contracts with Fortune 500 enterprise buyers and mid-market manufacturers. Acquisition runs through a direct field-sales and inside-sales hybrid supported by a Request a Quote funnel on stelray.com, trade show participation (BIOMEDevice Boston, Design-2-Part), and consultative DFM reviews. Customers are concentrated in North American OEMs across regulated and engineering-intensive verticals; no reseller, distribution, or marketplace channels are used.

Name

Stelray Plastic Products

Legal name

Stelray Plastic Products, Inc.

Website

https://stelray.com

Company type

Private

Founded year

1961

Operating status

Operating

Headcount range

11–50 employees

Short description

Stelray Plastic Products is a second-generation, family-owned precision plastic injection molding contract manufacturer in Ansonia, Connecticut, serving Fortune 500 and mid-market OEMs across medical, electronics, aerospace, automotive, and consumer appliance with end-to-end resin-to-box production, in-house tooling, and regulated quality systems.

Ownership category

akta.pro rank

Product category

Plastic Injection Molding Contract Manufacturing

NAICS

Plastics Product Manufacturing (3261), All Other Plastics Product Manufacturing (326199)

SIC

Miscellaneous Plastics Products (3080), Plastics Products, Nec (3089)

akta.pro primary industry

Custom Injection Molding & Contract Manufacturing (Job Shops/CMs) (IMANAFAJ)

akta.pro secondary industries

Medical & Life Sciences Injection Molding (Devices, Diagnostics, Cleanroom) (IMANAFAC), Injection-Molded Plastics Manufacturing (IMANAOAG)

Keywords

• Plastic injection molding
• Custom mold making
• Contract manufacturing services
• Medical device molding
• Post-mold finishing

Headquarters

HQ city

Ansonia

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Personnel, Operations, Supply Chain, Infrastructure, Technology or R&D, Marketing or Sales

Revenue model

1. Injection Molding Manufacturing Services: Revenue is generated through custom precision plastic injection molding services, including production runs of molded components. Pricing is driven by part complexity, resin selection, cavitation, and production volume.
2. Mold Making & Tooling Services: In-house custom injection mold building and mold transfer/reconditioning services. New mold builds and transferred tool rehabilitation are billed as discrete project engagements.
3. Post-Mold Secondary Operations: Value-add services including ultrasonic welding, pad printing, hot stamping, heat-staking, painting, plating, shielding, assembly, and final packaging and fulfillment — bundled with molding programs or sold as standalone services.
4. Engineering & Prototyping Services: Design consultation, rapid prototyping, Design for Manufacturing (DFM) reviews, and mold flow analysis offered as pre-production engineering services.

Pricing tiers

Go-to-market motion1 record

Distribution channels2 records

Marketing channels6 records

Core offering

Stelray Plastic Products is a contract manufacturer of precision plastic injection molded components, operating a 22- to 620-ton press fleet in a 42,000+ sq ft Ansonia, CT facility. Core offerings span custom injection molding, in-house mold making, 3D-printed tooling, engineering/DFM and rapid prototyping, post-mold secondary operations (ultrasonic welding, pad printing, heat-staking, assembly, packaging), and medical/white-room molding with ISO 9001:2015, FDA 21 CFR 820, and cGMP compliance. The 'Resin-to-Box' strategy consolidates raw resin intake through final packaged, point-of-sale-ready goods under a single supplier.

Product overview

Stelray Plastic Products is a full-service contract manufacturer of precision injection molds and molded products, offering a comprehensive suite of services under one roof. The core offerings include Custom Plastic Injection Molding (spanning 22 to 620 ton clamp force), supported by in-house Mold Making Services. Complementary services include Medical Injection Molding (with planned Class 8 clean room), Engineering and 3D Prototypes for product development, Quality Control with advanced metrology capabilities, and Post Mold Services (ultrasonic welding, pad printing, assembly). The company also offers 3D Printed Tooling for accelerated mold production and a Tool Transfer Program for accepting customer-owned molds. Services span from small components to ready-to-stock goods, operating across multiple shifts in a 42,000 square foot facility.

Differentiator

Problem solved

Functional benefit

Products and services

• Custom Plastic Injection Molding Precision plastic injection molding services using a 22- to 620-ton clamp force fleet, producing 28 million parts per year for medical, aerospace, automotive, consumer appliance, and electronics OEMs.
• Mold Making Services Full-service, in-house tool room providing custom injection mold construction, SPI mold classification support, mold reconditioning, and tool transfer rehabilitation by master toolmakers.
• Medical Injection Molding Clean room and white room injection molding services for medical devices and healthcare accessories, operated under FDA 21 CFR 820 registration and cGMP compliance.
• Ultrasonic Welding Service Secondary operation for joining plastic parts without fasteners or adhesives, featuring energy director designs for hermetically tight enclosures, typically bundled with molded part programs.
• Quality Control and Metrology Services Precision quality management offering complete lot traceability, high-speed VMM/CMM part measuring, documented process controls, mold maintenance tracking, IQ/OQ/PQ product validation, and PPAP investigations.
• Post-Mold Secondary Services Value-add secondary operations including pad printing, hot stamping, painting, plating, heat-staking, soldering, assembly, and final packaging/fulfillment, bundled with molding programs or sold as standalone services.
• Engineering and 3D Prototypes Product design services including Design for Manufacturing reviews supported by master toolmakers and AI-driven software, rapid prototyping, mold flow analysis, and resin selection guidance from commodity-grade to biodegradable polymers.
• 3D Printed Tooling 3D printed steel mold core and cavity blocks using H13 Tool Steel material with hardness up to 44 HRC pre-heat treat and surface finishes as fine as SPI A1, featuring conformal cooling networks that reduce cycle times.
• Tool Transfer Program Mold transfer services accepting existing customer-owned molds from other facilities with comprehensive tool review, reconditioning checklists that restore molds to near like-new condition, and ongoing maintenance scheduling.

Quantifiable outcome

• 28,000,000 parts shipped per year, demonstrating high-volume production reliability.
• +2 more outcomes

Named customers3 records

Segments5 records

Ideal customer profiles4 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature6 records

Scale indicators6 records

Recent moves11 records

Expansion highlights5 records

Direct peers

• Rogan Corporation: Medical-focused custom injection molder with Class 8 clean room capabilities, in-house tooling, and assembly—directly comparable to Stelray's medical device manufacturing vertical and clean room roadmap.
• Westfall Technik: US-based full-service plastics manufacturer with multiple molding technologies, in-house tooling, and value-add assembly serving medical, aerospace, and industrial OEMs—comparable integrated contract manufacturing footprint.
• EVCO Plastics: Mid-sized US contract injection molder offering custom molding, design engineering, and post-mold services across medical, industrial, and consumer markets—directly comparable in business model and mid-market positioning to Stelray.
• Plastic Components Inc. US custom injection molder specializing in engineered plastics for aerospace, medical, and industrial applications—matches Stelray's aerospace/automotive/defense vertical mix and precision molding focus.
• MGS Manufacturing / MGS Plastics: US contract injection molder specializing in regulated industries (medical, dental, electronics) with molding, tooling, and assembly—comparable regulatory focus and customer profile to Stelray.
• Thogus Products: Family-owned US injection molder with in-house tooling and contract manufacturing services serving medical, defense, and industrial customers—comparable in family-owned structure and full-service contract model.
• Mack Molding: Vermont-based contract manufacturer offering injection molding, mold building, and assembly with a regulated-industry focus (medical, defense, industrial)—comparable in full-service resin-to-box positioning and Northeast geography.
• Tessy Plastics: New York-based custom injection molder with broad tonnage range, in-house tooling, and assembly serving medical, industrial, and consumer OEMs—closely matching Stelray's regional Northeast presence and full-service model.
• Mayne Plastics: Mid-sized US custom injection molder offering molding, post-mold decoration, and assembly—comparable in scale, custom contract manufacturing focus, and secondary service offerings to Stelray.

Broad incumbents

• Phillips Plastics / Phillips Medisize: Large global contract manufacturer with deep medical device, pharmaceutical, and diagnostics molding capabilities—comparable vertical mix though at significantly larger scale than Stelray.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks5 records

Key highlights6 records

Customer concentration

• Facebookfacebook.com/StelrayPlasticProducts
• LinkedInlinkedin.com/company/stelray-plastic-products
• Xx.com/StelrayPlastic

Compliance6 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles5 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Stelray Plastic Products