Custom Plastic Molding Solutions

At Comar, there’s nothing we love more than a challenge. Our customers regularly bring us their most ambitious projects, knowing we will meet or exceed their expectations.

Custom Plastic Molding Solutions

Our plant network encompasses all major rigid plastic processing platforms, and we embrace the opportunity to design and deliver proprietary products that meet the needs of our customers and their markets. Custom plastic injection molding, printing, and complex assembly work are Comar specialties, and we can accommodate nearly any resin material.

When you choose Comar, you gain access to our wide range of design and engineering services and state-of-the-art technologies. That access includes full engineering support for your R&D team or your packaging design group.

In addition to design and blow-molding, Comar offers precision custom decorating and packaging.

With You Every Step of the Way

From the moment you partner with us, our Regional Sales Managers and Technical Operations Project Managers will work closely with you to design and produce your custom or transferred molds to your exacting specifications — on time and within budget.

We work with you step by step, from defining product requirements through production, and we understand the critical importance of designing a unique rigid plastic part that offers proper form, function, and production efficiency. In addition to new product development, our technical team can help both new and repeat customers to modify and improve existing product offerings. Over the years, we have developed cost-effective solutions for our customers through light-weighting, increased cavitation, secondary packaging modifications, or resin changes.

Comar manufactures with strict adherence to cGMPs. Many of our quality systems meet the requirements of 21 CFR – Part 820 and ISO 9001 and ISO 13485 for medical devices. We are working diligently to standardize these systems across our growing organization.

Take the Comar challenge today: Call 800-962-6627  or e-mail us with your toughest requirements and let our team of experts show you how we break the mold when it comes to custom rigid plastic design.

Helical Lock Case Study


A common problem in the analytical market is maintaining seal integrity with a traditional screw-thread vial under autoclave temperatures. Typically, the closure will back-off the threads of the vial and cause the product to leak or have an operator manually screw the closure back on the vial after autoclaving.

Comar's Helical Lock Vial and Closure System was developed to improve seal integrity under autoclave temperatures, prevent the need to retorque the closure, and increase the ease & efficiency of opening the closure with a 1/4 turn on & off design. To learn how Comar developed the Helical Lock System, view the following step-by-step case study.

Step 1. Defining the Product Requirements The success of the revolutionary helical lock – a major advance over traditional vials – can be directly traced to the very first step of development, wherein three critical challenges are to be defined:

  • How to improve seal integrity jeopardized by screw-thread back-off due to autoclave temperatures
  • How to increase the ease and efficiency of opening the closure, and
  • How to reduce rejection rates in the field due to leaky vials, thereby improving cost savings

Defining the Product Requirements

Step: 2. Producing a Breakthrough Packaging Design The design and engineering teams go to work by producing 2D sketches and 3D renderings based on the challenges defined in the previous step. These are followed by prototypes and unit tooling. Material recommendations are also discussed at this step.

Producing a Breakthrough Packaging Design

Step: 3. Build Unit Tools; Finalize and Refine Material Specs The helical lock is starting to acquire shape. In order to finalize the design, steel-safe plastic molds for the closure, as well as forming and finish dies for the vial-forming process are built. Samples are manufactured in order to begin the testing phase.

Build Unit Tools

Step: 4. Test the Product Functionality and Material Selection This step focuses on testing. First, the manufacturing process is verified to ensure production capability. Samples of the helical lock are subjected to intensive internal testing, then are sent to external vendors for further testing and confirmation. Finally, a design of experiment is employed to ensure seal integrity throughout the manufacturing tolerances.

Test the Product Functionality and Material Selection

Step: 5. Build Production Tooling and Go To Market Going into the final step of development, production tooling and secondary equipment is built and qualified. Meanwhile, forming and finish dies are manufactured. At last, dozens of hours of hard work finally reach their culmination, as the helical lock is now proven to be ready for production and penetration into the market

Buld Production Tooling and Go To Market

Request Information for custom molding solution


* Required fields *

No Items Match Your Search

Packaging Quality, Service and Creativity Since 1949