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When first profiled by MoldMaking Technology in May, 1999, Germantown, WI-based MGS Mfg. Group’s primary revenue-generating activity was toolmaking. The past 10 years have seen an explosion for the company as it experienced a significant phase of growth and change—developing into a full-service “engineered solutions” provider of design, tooling, sampling, mold and part qualification, production molding, automation and turnkey manufacturing systems.

A shot of the MGS automated tooling facility. The photo’s foreground shows the HS/HP three machine center with two robots, multiple stationary and rotating staging platforms, integrated CMM, and web-based vision system. In the background are the six-wire EDM cell, rail-mounted six axis robot, and two integrated CMMs. Photos courtesy of MGS Mfg. Group.

Much of this growth can be attributed to MGS Group’s oldest member company Moldmakers Inc. “This tool shop is an engineering beast,” notes MGS Group Marketing Director John Berg. “At more than 60,000 square feet, it features all of the traditional equipment you’d expect from a large, modern shop (wet/dry surface grinders, horizontal/vertical machine centers, CNC lathes, jig grinder, etc.) along with a deep staff of personnel (60+ journeyman toolmakers/CNC techs/EDM techs, 20+ designers/engineers, 20+ program managers), plus extensive automation capabilities. The automated tool shop features three high speed/high precision hardened steel machining centers with integrated robotics and CMM, three high speed/high precision graphite machining centers with integrated robotics and two CMMs, three dual machine sinker EDM cells with integrated robotics, and the ‘Monster’ cell—six wire EDMs with two CMMs and a rail-mounted, six-axis robot to feed it.”

Just the Facts MGS Mfg. group The exterior of the MGS Technical Center. Location: MGS Technical Center (corporate headquarters), Germantown, WI; TecStar Mfg. Co. Germantown, WI; TecStar de Mexico, Chihuahua, Mexico; All West Plastics, Antioch, IL; Statistical Plastics Corp., Germantown, WI; Universal Multishot Systems, Germantown, WI; Prototypes, Molds, & Design, Menomonee Falls, WI; MGS Distribution Center. Germantown, WI. Year Established: 1982 Services Offered: Mold and part engineering/design/ tooling, prototype/pilot/production molds, sampling/ development/qualification, injection/blow/continuous extrusion shuttle blow molding, value-added operations/ assemblies/automation, turnkey manufacturing cells/specialty equipment, multishot (multiple material) technologies. Industries Served: Electronics, computer, consumer, medical/healthcare, packaging/closures/containers, automotive, telecommunications, industrial, aeronautics, and appliance. Number of Employees: 800+

A Turning Point
“One of the most significant events in the history of our company occurred in the late ‘90s when we created our first portable injection units to sample the multishot molds we were building,” recalls Berg. “The success of our ‘sampling’ units led to the development of full featured production models. The MGS line of Universal Multishot Systems (UMS) includes vertically and horizontally mounted injection units that convert a standard injection molding machine into a multishot press. Other UMS equipment includes Rotary Platens and Vacuum Units. The success of our UMS line has facilitated our growth as a leading provider of multishot tooling systems and equipment.

MGS toolmakers also took a lead role in developing MGS Automation Systems, Berg notes, which are custom equipment solutions provider for the downstream events associated with production molding, like assemblies, decorating, degating and packaging.

Developing and Acquiring
Berg predicts the company will continue to grow by investing in the development of new technologies to improve manufacturing efficiencies in the following areas: in-mold assembly, multishot development for medical products, water injection technologies, and automating value-added operations.

The company also recently developed and acquired several companies to strengthen its position in the marketplace. PMD (Prototypes, Molds, & Design) was developed as a company-within-a-company dedicated to time-to-market deliveries of tooling systems. “PMD is staffed to operate in a leaner environment,” Berg stresses. “It is equipped with the required machinery, but with a smaller staff. PMD does not house the automation capabilities of Moldmakers, Inc., and as a result, has a lower overhead structure, allowing PMD to be more competitive with customers not requiring the full engineering horsepower of MGS.”

In 2006, MGS acquired All West Plastics, an ISO Class 8 cleanroom/white room molding operation. Its most recent acquisition is Sousa Plastics in Chihuahua, Mexico. “This facility is now called TecStar de Mexico and serves a variety of markets (electronics, automotive, appliance),” Berg notes. “We will continue to look for strategic expansion opportunities in the next 10 years.”