Case Studies

Case Studies gives New Berlin Plastics the opportunity to share our recent work with customers, clients, and visitors. After finishing projects, we review and evaluate them in their entirety. We gather information and compile a brief synopsis to bring you valuable and qualitative descriptions of projects. Our case studies portray the uniqueness and complexities of the work that we support and offer to our clients. Check out our most recent work!

Catch and Pawl

Through automation of the production operation of Strattec’s Catch and Pawl numerous benefits were achieved: stable cycle time, removal of human error, a highly repeatable process, and a competitive price.

Tiger Latch Handle

The Tiger Latch Handle was destined for a major marine engine manufacturer, therefore our customer required a molder that had experience producing paint-ready surfaces and could quickly move the design from concept to production. Our customer-focused team transformed the initial design and in the end, New Berlin Plastics delivered a robust, clever, and economical design.

Cable Tie Tension Knob

Our customer approached us when they encountered a design dilemma while developing an innovative cable tie tool that allowed for tension adjustment via a control knob. What would be the best way to achieve a numerically graduated tension knob with high-integrity markings? The team at New Berlin Plastics offered a solution that put their worries to rest.


New Berlin Plastics invested in the eDart as part of our ever-evolving scientific injection molding practice. The eDart allows us to collect vast amounts of data during machine cycle which is then analyzed to create data-driven procedures that lead to consistent and reliable production.

Demand Management Team

In September of 2013, New Berlin Plastics implemented the Demand Management Team, comprised of Director of Manufacturing, Purchasing Manager, and Demand Manager, as part of a major organizational restructuring. How does this benefit our customers? The team generates improved on-time delivery, increased order efficiency, and opportunities for cost reduction.

Computrac Vapor Pro

In the pursuit of outstanding quality, New Berlin Plastics invests in technology to ensure that the material being used to mold your products are of the highest grade. The Computrac Vapor Pro is a revolutionary moisture analyzer that utilizes a cylindrical bottle heater, dry air-carrier gas flow system, and a moisture sensor with a detection limit of 10 ppm.

Scientific Injection Molding


The term scientific injection molding (SIM) is becoming a buzzword in the industry. How do you differentiate between true SIM and loosely used terminology? It comes down to data collection, machine performance, processes, material characteristics, and how they influence one another. By understanding this behavior through data analysis, New Berlin Plastics is able to create processes that cater to particular materials and parts; providing a repeatable process that’s proven in the numbers.

Aston Martin ECU

Aston Martin unveiled a new DBS line in 2007 (original line 1967-1972) and they weren’t shy about pulling out all the stops. The ECU (Emotion Control Unit) is a piece of art; the body is molded from material NASA uses for helmets and the end cap is made of crystal sapphire that accentuates the etched Aston Martin Logo. It’s clear that Aston Martin set out to create THE luxury key.