Polyfab Corp.

What Polyfab Corp. does

Polyfab Corp. (legal name Polyfab LLC.) is a US-based custom thermoplastic injection molding manufacturer founded in 1971 and headquartered at 1705 Martin Avenue, Sheboygan, Wisconsin. The company operates as a single-source contract manufacturer with press capacity spanning 39 to 720 tons and shot sizes up to 160 ounces, supported by an in-house tool room, Class 100,000 cleanroom cells on smaller-tonnage presses, Yushin and Fanuc robotics with custom end-of-arm tooling, and Kistler and RJG cavity-pressure sensing for scientific, data-driven molding. Production is structured around cellular and lights-out 24/7 manufacturing, with claimed throughput of up to 54,000 uniquely molded parts per day from a single 500-ton press. The company is ISO 9001:2015 registered (certificate 3429, ANAB/IAF-accredited) and runs IQMS ERP for real-time inventory and JIT/blanket-order fulfillment.

The company's commercial offering is organized into five service lines: Injection Molding, Engineering (DFM, feasibility, process optimization, and project review), Tooling and Asset Management (custom mold build with up to 24-week lead times and PPAP-validated testing), Materials Management (vendor network, market forecasting, JIT scheduling), and Value-Added Services (in-cycle and post-mold assembly, in-mold decorating, bar coding, custom packaging, and bulk storage via 13 resin silos on a railroad spur). Polyfab serves four primary verticals: Consumer Packaging (e.g., hinged lids for wet wipes and personal care), Commercial & Industrial Products (e.g., natural gas connections, centralizers, bottle fillers, engine covers), Home & Commercial Building Improvement (e.g., exterior lighting, HVAC components, roofing, siding), and Medical & Healthcare (e.g., fluid delivery fittings, orthodontic devices, medical device enclosures).

Polyfab's business model is B2B contract manufacturing sold through direct enterprise field sales, with quote-based, project-specific pricing and no public price list. The company markets primarily through its website, industry-association memberships (IMDA, SPE, MAPP, ASQ, Business Excellence Consortium, SHRM), and earned-media recognition including the 2023 IMDA Best Use of IMD – Film Application award for an anti-microbial Zurn Elkay water bottle filler alcove. Since August 3, 2020, Polyfab has been a wholly-owned subsidiary of DAIHO USA CORP., itself a subsidiary of Japan's DAIHO Industrial Co., Ltd. (DAIHO Group, founded 1937, Osaka), providing cross-border scale and combined plastics-processing capabilities. Scott Doleshaw continues as President and CEO.

Name

Polyfab Corp.

Legal name

Polyfab LLC.

Website

https://polyfabcorp.com

Company type

Private

Founded year

1971

Operating status

Operating

Headcount range

101–250 employees

Short description

Polyfab Corp. (Polyfab LLC.) is a Sheboygan, Wisconsin-based custom thermoplastic injection molding contract manufacturer founded in 1971 and owned by Japan's DAIHO Group, serving medical, consumer packaging, building products, and industrial customers with 39–720 ton presses, cleanroom molding, and integrated engineering, tooling, and value-added services.

Ownership category

akta.pro rank

Product category

Custom Plastic Injection Molding

NAICS

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

SIC

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

akta.pro primary industry

High-Performance & Engineering Polymers Injection Molding (PEEK, PPS, LCP, etc.) (IMANAFAK)

akta.pro secondary industry

Medical & Life Sciences Injection Molding (Devices, Diagnostics, Cleanroom) (IMANAFAC)

Keywords

• Custom injection molding
• Thermoplastic contract manufacturing
• Medical device molding
• Consumer packaging molding
• Plastic building materials

Headquarters

HQ city

Sheboygan

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

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

Revenue model

1. Custom Injection Molding Manufacturing: B2B contract manufacturing services producing custom injection molded plastic parts and products. Revenue generated through project-based manufacturing contracts with enterprise customers across multiple industries including medical, consumer packaging, building materials, and industrial products.
2. Tooling and Mold Manufacturing: Custom mold design and manufacturing services for customer injection molding projects, typically taking up to 24 weeks for new mold construction.
3. Value-Added Services: Auxiliary services including in-cycle assembly, post-mold component assembly, bar coding, custom packaging, and logistical support. These services supplement core injection molding capabilities as a single-source manufacturer.
4. Materials Management and Managed Inventory: Material procurement, vendor management, and managed inventory solutions including daily monitoring, JIT scheduling, and blanket order fulfillment.

Go-to-market motion2 records

Distribution channels1 record

Marketing channels4 records

Core offering

Polyfab is a custom thermoplastic injection molding contract manufacturer producing engineered plastic parts for enterprise customers via automated lights-out manufacturing across a 39-ton to 720-ton press range. The offering is bundled as a single-source manufacturer combining custom mold design and tooling, collaborative engineering from design through production, materials management with JIT scheduling, and value-added services including in-mold decorating, assembly, bar coding, and custom packaging. The company operates Class 100,000 cleanroom molding for medical applications and holds ISO 9001:2015 certification.

Product overview

Polyfab Corp. is a custom injection molding company offering a comprehensive suite of manufacturing services centered on plastic injection molding. The core offering comprises Injection Molding Services supported by integrated Engineering Solutions, Tooling and Asset Management, Materials Management, and Value-Added Services (including assembly, drilling, welding, decorating, and custom packaging). Specialized capabilities include Clean Cell Molding (Class 100,000) for medical applications and In-Mold Decorating (IMD) for decorative film applications. The company serves diverse markets including Medical Devices, Consumer Packaging, Plastic Building Materials, and Industrial/Commercial Products. Founded in 1971 and headquartered in Sheboygan, Wisconsin, Polyfab operates presses from 39-ton to 720-ton capacity with automation robotics for lights-out manufacturing.

Differentiator

Problem solved

Functional benefit

Products and services

• Custom Injection Molding Services Core custom thermoplastic injection molding production offering automated lights-out 24/7 manufacturing across a 39-ton to 720-ton press range, accommodating both high-volume and low-volume production runs with rapid turnaround and supply chain reliability for enterprise customers.
• Engineering Solutions In-house collaborative engineering department providing design-for-manufacturability (DFM), material evaluation, feasibility studies, process optimization, mold maintenance/repair/revision, and project review meetings from design and prototyping stages through manufacturing and delivery for enterprise customers.
• Tooling and Asset Management Custom injection mold design and manufacturing services through an in-house tool room, including mold testing per PPAP standards, preventative maintenance, repair, and restoration for enterprise customers' injection molding projects.
• Materials Management Streamlined materials procurement and management leveraging a robust vendor network, real-time monitoring, market forecasting, JIT production scheduling, blanket order fulfillment, and managed inventory via IQMS ERP for enterprise customers.
• Value-Added Services Auxiliary capabilities including in-cycle assembly, post-mold component assembly, drilling, welding, bar coding, custom packaging, and logistical support that supplement core injection molding as a single-source manufacturer offering for enterprise customers.
• Clean Cell Molding Class 100,000 cleanroom injection molding on 39-, 55-, 140-, and 200-ton presses for medical and precision applications requiring contamination-free manufacturing environments.
• In-Mold Decorating (IMD) Specialty in-mold decorating capability for custom part marking and decorative features applied during the molding process, allowing premium product finishes without additional manufacturing steps for enterprise customers.
• Medical Device Injection Molding Specialized injection molding for medical devices, healthcare equipment, and pharmaceutical products including fluid delivery fittings, orthodontic devices, device enclosures, infant care products, hinged lids for wet wipes, medical device enclosures, precision fittings, and custom packaging for medical devices.
• Consumer Packaging Solutions Custom injection molded plastic packaging solutions including hinged lids for wet wipes, personal care product containers, and product-specific boxes and custom packaging for consumer home care products.
• Plastic Building Materials Injection molded plastics for home improvement, construction, and commercial building sectors including exterior home lighting installations, lawn and garden equipment, commercial building interior products, HVAC components, window/door framing, roofing materials, flooring, siding, and wall installation products.
• Industrial and Commercial Products Custom injection molded plastics for industrial and commercial sectors including natural gas connections, support bearings, centralizers, bottle fillers, plastic engine covers, small engine and marine components, and lawn care and landscaping equipment.

Quantifiable outcome

• Up to 54,000 uniquely molded products per day from a single 500-ton press
• +2 more outcomes

Named customers1 record

Segments4 records

Ideal customer profiles3 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature7 records

Partnerships

One partnership is on record.

• DAIHO GroupcoreOthers · 3 August 2020Polyfab LLC joined DAIHO Group in August 2020. DAIHO Group (founded 1937, Osaka, Japan) is a plastics processing company manufacturing molds, self-blowers, paper tube covers, and other plastic products serving home electronics, automobiles, office automation equipment, and housing goods. No immediate changes planned for either company; contracts, services, and resources available to Polyfab customers and suppliers not affected. As part of a larger organization, customers and vendors expected to benefit from enlarged scale and combined capabilities. Polyfab continues to provide scientific injection molding solutions under DAIHO USA CORP. subsidiary.

Scale indicators6 records

Recent moves5 records

Expansion highlights5 records

Direct peers

• SMC Ltd. Contract manufacturer specializing in medical device injection molding, assembly, and packaging with cleanroom capabilities. Direct competitor for medical device OEM programs where Polyfab's Class 100,000 cleanroom is a key differentiator.
• PTI Engineered Plastics: Michigan-based custom injection molder with engineering, tooling, and assembly capabilities serving automotive, industrial, and consumer customers. Comparable multi-vertical contract manufacturing footprint and program-management orientation.
• Baytech Plastics: Michigan-based custom injection molder providing molding, engineering, and assembly services across industrial, automotive, and consumer end markets. Comparable contract manufacturing model and Midwestern industrial customer base.
• Plastikon Industries: California-headquartered contract injection molder with cleanroom medical capabilities serving medical device, diagnostics, and consumer health customers. Most direct analog to Polyfab's medical/cleanroom offering and consumer packaging hinged lid work.
• Plastic Components Inc. (PCI): Wisconsin-headquartered custom injection molder serving industrial, consumer, and medical customers with full-service tooling and molding. Geographic and capability peer with similar multi-vertical contract manufacturing model.
• Tessy Plastics: New York-based custom plastic injection molder offering engineering, tooling, molding, and assembly across medical, consumer, and industrial end markets. Direct competitor for multi-vertical B2B molding programs of similar scale.
• Engineered Plastic Components (EPC): Wisconsin-based custom injection molder offering design, tooling, molding, and value-added assembly. Directly comparable on geography, size range, and full-service contract manufacturing value proposition.
• Viking Plastics: Pennsylvania-based custom injection molder providing design support, molding, and assembly for fluid handling, appliance, and industrial customers. Comparable mid-sized custom molding profile with similar value-added service bundling.
• EVCO Plastics: Wisconsin-based custom thermoplastic injection molder of comparable size serving consumer products, medical, and industrial customers. Closest geographic and capability analog to Polyfab, including similar multi-vertical breadth and contract manufacturing model.

Broad incumbents

• Phillips Plastics (Molex): Long-standing Wisconsin-based custom injection molder now part of Molex, offering a much broader portfolio across automotive, medical, and industrial customers. Larger incumbent that overlaps with Polyfab in tooling and contract molding services.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks6 records

Key highlights7 records

Customer concentration

Compliance1 record

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

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 Polyfab Corp.