We are currently experiencing slightly extended delivery schedules due to the COVID-19 outbreak and "shelter in place" order within our city. We appreciate your patience given these unusual circumstances and are working diligently to overcome these delays.


Engineering Services

Conceptual Refinement

Shadow can take your idea, sketch, or concept to the next level by refining your product for aesthetic appeal, functionality, and performance while keeping a close eye on the cost to manufacture using a variety of development techniques.


Computer Aided Design

Shadow uses state-of-the-art software technology to enhance your product design. We construct your design in full 3-D using advanced CAD software like Solidworks, PTC Creo, NX and Rhino. With this electronic product design, rapid manufacturing processes can be easily utilized to reduce your time to market and promote an early customer demand.


Reverse Engineering

Reverse engineering is often an important step in a successful product development. Utilizing a variety of techniques and modern technology, Shadow can reverse engineer most products for your detailed review quickly and at a fair price.


Design for Manufacture

Shadow has significant hand-on experience in manufacturing products of all types. From a simple design to a complex assembly, Shadow can assist your organization to verify that a part is suitable for manufacture. We support products designed for injection molding, 2-shot and insert molding, extrusion, thermo/vacuum forming, blow molding, metal fabrication / welding, as well as, CNC machining.

2-D Drafting

We have several options available for those who utilize 2-D product drawings. Most design efforts these days are geared toward 3-D development, which means the 2-D drawing can lag behind. If this is the case, we have the right amount of support for your team to keep you ahead of the game.



Shadow’s mold design capabilities are strong, capable and state-of-the-art. Our unique blend of industry experience and modern technology allows us to provide a manufacturing friendly mold design quickly while following the customer’s in-house design and engineering standards.

Computer Aided Design

Shadow uses state-of-the-art software technology to enhance your mold design. We construct your design in 3-D using advanced CAD software like Solidworks and NX with add-on mold design modules. With this 3D mold design, mold makers can quickly manufacture components thereby reducing your time to market and promote an accelerated delivery schedule.

Experienced Designers

Our designers’ backgrounds include decades of mold building, tool engineering, product development, troubleshooting and mold flow analysis experience for both large and small corporations. This experience provides clients with noticeable advantages in producing a high quality mold for maximum productivity without the run-around.

Advantages of Using Our Team

We adapt to your standard and objectives. We are resourceful and willing to offer suggestions to improve tooling including advanced Mold Flow simulation. Our design team consists of experienced engineers and tool makers. All designers are also trained product designers. Designs are available in 3-D and 2-D for every job. We always strive to be innovative and professional.

Detailed Drafting

Shadow provides complete 2-D drawings for every mold design project. Most designs these days focus only on the 3-D files, which means the 2-D work will typically fall behind thereby creating a possible quality assurance problem. However, this is not the case with our design cycle. By using Shadow, our 3-D and 2-D files are developed simultaneously so both exist when the design is delivered for customer approval or final manufacturing.

Mold Filling & Packing

In a Mold Filling analysis, our engineers generate the part geometry in either 2.5-D shell or 3-D solid tetrahedral elements. We then model the complete runner system including the type (hot/cold), size, and location. Then, as needed, we will modify the design to develop a more advantageous layout to optimize the manufacturing performance during the first and second stages of fill. By optimizing the manufacturing performance at this stage, Shadow can maximize your product’s quality and strength due to molding.

Mold Cooling

Using an existing or a proposed cooling layout, we have the capability of performing a Mold Cooling analysis on your mold to ensure even cooling. Valuable information regarding conditions leading to an extended cycle time, unbalanced or non-turbulent coolant flows, and hot spots in the mold are identified and corrected.


Warpage & Shrinkage

Using the Filling, Packing and Cooling results, our engineers can perform a warpage study identifying how your part is likely to deform after ejection. In addition, the warpage results can be broken down into the major contributors: (1) differential shrinkage, (2) differential cooling and (3) molecular/filler orientation. This study is popular among clients who examine part tolerances to maintain good dimensional stability during molding.


Fiber Orientation

Using this type of advanced analysis, we can identify and present results based upon your part’s glass fiber orientation. This analysis identifies fiber effects through the thickness of the part as well as on the surface of the mold. Negative fiber effects can significantly contribute to differential shrinkage, poor knit line integrity and reduced strength in critical areas of the part.

Insert, 2-shot, Overmolding

Using state-of-the-art analysis techniques, Shadow engineers can accurately identify molding results based upon you part’s plastic-to-plastic or metal-to-plastic interaction during the molding process. Critical information is obtained from this analysis which allows our team to correctly predict how your part will deform as an assembly.

Why FEA is Needed

In today’s 3-D world, products are required to do more for longer and it is the responsibility of the design engineer to evaluate their design decisions. Fortunately, we live in the age of computers and have a vast arsenal of simulation tools available to the modern engineer. At Shadow, we bring this service to you without the expensive overhead associated with maintaining software internally thereby making our analysis solutions very cost effective. Frequent questions such as: How tall must I make that rib? How strong is this part under these loading conditions? Where are the stresses located and how will that affect part functionality? And how much wall thickness will I need to ensure stability are analytically answered with certainty and precision.

Experienced Engineers

Our engineering analysts’ backgrounds encompass Plastic Part Fabrication, Metal Fabrication, Complete Engineering Refinement, Troubleshooting, and Custom FEA Programming. In addition, most of our analysts are registered Professional Engineers. Our staff is accustomed to working with your Engineering Department to provide the most accurate solution possible.

The Right Solution

Shadow offers a broad range of Finite Element Analysis (FEA) solutions to our customers in order to help answer many difficult questions that arise during product design and troubleshooting. In its simplest form, finite element analysis is the analytical method of dividing a part’s geometry into thousands of smaller regions known as elements. Then, a variety of properties are assigned to each element in order to give the sub-divided part strength, thickness, material properties, etc. so that the finite element model (FEM) approximates your part. The FEM is then subjected to a series of unique analysis solvers that simulate how your part will behave in operation. Our extensive array of state-of-the-art hardware and software technologies give us the greatest flexibility to identify the right solution for your needs.

During my time as a contact engineer at AMECO-USA I was able to work directly with Rob. The knowledge base he has gathered over the years is quite extensive and was key to the project we were tasked with at the time. Speaking with Rob on many different business and engineering topics explained how his company became successful. I look forward to working with him again and would recommend him for most any engineering project.

Steven HernandezContract Engineer, AMECO

Our Design Engineering group has worked with Rob for the last 2 ½ years. He has helped us improve some existing molds and worked closely with us on new product designs on manufacturability, resin selection, mold flow analysis, mold design resulting in quality parts. Rob is very responsive and provides significant value. Rob participated with us and our molder in three-way Design Reviews. I highly recommend.

Rob. Preston PierceVP Design Engineering, Alcohol Monitoring Systems

I have been working with Shadow for nearly 5 years and each time it has been informative for both me and my customers. Their professionalism and state-of-the-art services have helped us remain competitive in today’s tight economy. At Sare Plastics we always strive for excellence and that is why we continue to work with Rob and his team for our engineering needs.

Bart StuchellPresident, Sare Plastics

Rob has been working with Moldex3D for 8 years and before hand he was already a veteran in this field. His background and domain knowledge in polymer processing development has been impressive to everyone in our company. Working with Rob is indeed reliable and delighted, which helps the projects finished with satisfaction. I herein recommend Rob as your valuable engineering partner to work with.

Kenny LuCEO, Moldex3D Northern America

Robert has worked and managed the technical projects for a number of major programs for my previous company; providing Plastics filling & FEA simulations. His technical expertise is excellent and quite extensive, providing his clients with design ideas that were out-of-the-box and very affective. He is easy person to work and achieves the goals set out by the client.

Jim KempthornApplication Engineer, Ferro Corporation

Over the years, GECOM Corp. has collaborated with Shadow Polymers on many occasions. When called upon, Shadow has always provided an analytical expertise which has allowed GECOM to successfully improve at both the component and tooling design levels. In the fast paced and demanding world of automotive manufacturing, Shadow has proven to be an invaluable ally.

GECOM Corp. Injection Molding Engineering Department, Greenburg, IN