With our decades of injection molding expertise, PDI Molding frequently engages in a collaborative design process with our clients. By working together to define the product specifications and evaluate material choices, we optimize the product in terms of performance and manufacturability.

We produced the custom antenna housing highlighted here for use with a handheld radio. Through our joint endeavor with the client, we developed a process for injection molding the component, which featured dimensions of 13.875” in length x .720” in width, and with a wall thickness of 0.055”. Our talented mold designers overcame the challenge of building the tool so we could mold more than 10.0” of the internal diameter of 0.200” without any draft. To comply with the part’s surface finish requirements, we created the molds with a 0.003” deep chemically etched texture.

Constructed from aromatic polyester-base thermoplastic, chosen for its thermal and chemical stability, we molded the parts using our high-productivity vertical clamp injection molding machine, which allowed us to uphold close ±0.003” tolerances. We continue to manufacture this part for delivery to the customer within a one or two week turnaround, depending on order size.

If you are interested in learning more about this project or how our collaborative strategies can enhance your product development efforts, contact us today.

PDI Molding produces custom handheld housing that is almost 14 inches long with wall thickness of 0.055 inch. Antenna is made of aromatic polyester-base thermoplastic. We worked with customer throughout the design, development and material selection stage to ensure their design is moldable. One of the challenges that we had to overcome is to develop a process and build the mold so over 10 inches of the internal diameter of 0.200” can be molded without any draft! Each part is molded utilizing vertical clamp injection molding machine. Parts are molded with tolerances of ±0.003 inch.

Injection Molding of Thermoplastic Antenna Project Highlights

Project Name & Description

Housing used in Handheld Radio

Capabilities Applied/Processes


  • Product development & Design
  • Material selection
  • Mold Design

Injection molding

Equipment Used to Manufacture Part

Vertical clamp injection molding machine

Overall Part Dimensions

13.875 inch X .720 inch with over 10 inch in length on inside without any draft on ID of 0.200 inch

Tightest Tolerances


Material Used

Aromatic Polyester –base thermoplastic

Mold Texture

Chemically Etch Texture 0.003 inch deep

Industry for Use

Radio Communications

In Process Testing/Inspection Performed

Dimension and cosmetic inspection of each part per customer specifications

Delivery/Turnaround Time

1 to 2 weeks typical

Standards Met

Customer Specification