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Thin Wall Injection Molding Services | High-Speed Production

Evok Polymers delivers precision thin wall injection molding with ultra-fast cycle times and superior part quality. Our advanced technology and 25+ years of expertise enable us to produce lightweight, high-strength components with wall thicknesses as thin as 0.5mm. From packaging to consumer electronics, we optimize every aspect of your thin wall parts—material selection, mold design, and production efficiency—to deliver jewelry-quality components at competitive prices with rapid turnaround.

High-speed thin wall injection molding machine producing precision plastic components

Our Thin Wall Injection Molding Services

Complete thin wall molding solutions from concept to high-volume production, optimized for speed, precision, and cost efficiency.

Thin Wall Part Design

Expert design optimization for thin wall components, focusing on structural integrity, moldability, uniform wall thickness, rib design, and gate placement to ensure consistent fill patterns and minimize warpage in high-speed production cycles.

High-Speed Mold Development

Specialized mold design and fabrication for thin wall applications, featuring optimized cooling channels, rapid gate systems, and precision venting to achieve cycle times as low as 3-5 seconds while maintaining exceptional part quality and dimensional accuracy.

Rapid Prototype Services

Fast-turnaround prototyping to validate thin wall designs before production tooling. We help you visualize and test lightweight components for structural integrity, cosmetic appearance, and functional performance across various rapid prototyping technologies.

Material Selection & Testing

Comprehensive material science expertise for thin wall applications. We guide selection of high-flow resins, impact modifiers, and specialized compounds that deliver the strength, flexibility, and surface finish your thin wall parts require.

Production & Quality Control

High-volume thin wall production with rigorous process monitoring and statistical quality control. We maintain tight tolerances with 30-point inspection on critical dimensions, ensuring consistent part performance across millions of cycles.

Parts Qualification & Approval

Comprehensive first article inspection and qualification services. We work collaboratively to establish achievable tolerances, conduct molding trials, and provide detailed Cp/Cpk data to validate process capability before full production launch.

Service Process

Our 5-Step Thin Wall Molding Process

Design Optimization & Feasibility Analysis

We begin by examining your thin wall component design for moldability, analyzing wall thickness uniformity, rib structures, and draft angles. Using mold flow analysis, we identify potential fill issues, optimize gate locations, and recommend design modifications that ensure successful high-speed production while maintaining structural performance and cosmetic quality.

Material Selection & Flow Validation

Precision Tooling Development

Process Qualification & Fine-Tuning

High-Volume Production Launch

Trusted By Industry Leaders

Success Stories

Delivering precision thin wall components for leading OEMs across consumer products, packaging, and industrial applications.

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"Great expertise and people!"

Rick Chen
Rick Chen

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"Great expertise and people!"

Rick Chen
Rick Chen

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson

"Amazing business and amazing person to work with.Paul and I grew up together he has always had attention to detail in everything he has ever done,my company has used him a couple times now and are so pleased with the outcome I would recommend the company to anyone, once again..."

Kevin Nattress
Kevin Nattress

"Great customer service! Paul is super dedicated."

Mo Amin
Mo Amin

"Had a Great to work with Paul and it has been great! Has a plethora of knowledge and was great to learn from."

Landen Pool
Landen Pool

"Great expertise and people!"

Rick Chen
Rick Chen

"Paul is very knowledgeable and passionate regarding all facets of plastics manufacturing."

Matt Maskell
Matt Maskell

"driven with details ... Very impressive"

Lawrence Dathe
Lawrence Dathe

"Evok provided exceptional service! Paul and the studio team demonstrated amazing expertise and professionalism throughout the process. They exceeded expectations with precision and timely execution. Highly recommend for any project requiring top-notch design solutions."

Jason Salveson
Jason Salveson
The Evok Difference

Why Choose Evok Polymers for Thin Wall Molding?

25 years of injection molding expertise combined with cutting-edge technology and a relentless focus on your success.

Speed Experts

We specialize in ultra-fast cycle times for thin wall applications, reducing your production costs while accelerating time-to-market with optimized tooling and process efficiency.

Precision Engineering

Our Six Sigma-certified team leverages advanced mold flow analysis, tolerance stacking studies, and rigorous process control to deliver thin wall parts with jewelry-quality finish and dimensional consistency.

Cost Transparency

We're upfront about costs from day one, helping you optimize design decisions to achieve the lowest possible part price without sacrificing quality or performance in high-volume production.

White-Glove Partnership

Experience a trust-based collaboration where your success drives every decision. Our cross-functional team becomes an extension of yours, providing continuous improvement and responsive support throughout your product lifecycle.

Meet The Evok Team

Innovation-driven experts dedicated to your thin wall molding success.

Paul Dathe, Founder of Evok Polymers

Paul Dathe

Founder

Paul Dathe founded Evōk Polymers with a singular mission: delivering the highest quality injection molded components at the lowest possible price through proprietary technology and deep industry expertise. With over 25 years specializing in custom plastic injection molding, Paul has become a recognized problem-solver for complex thin wall applications. His career includes leadership roles at Caliber Products, where he launched 13 new products and grew sales 540%, and Entegris, where he managed a $40 million product line for semiconductor applications. Paul's technical foundation was built at Rollerblade, General Mills, and Boston Scientific, where he honed skills in design, prototyping, and manufacturing optimization. He holds four U.S. utility patents, is a Six Sigma black belt, and earned a B.S. in Mechanical Design from Bemidji State University with emphasis in rapid prototyping and 3D modeling. Paul is an active member of Allied Executives Business Leadership Peer group and the Institute of Packaging Professionals, continuously advancing thin wall molding innovation.

Jason Weber

Industrial Designer

Jason Weber brings a unique human-centered perspective to thin wall component design at Evok Polymers. As a seasoned industrial designer, Jason's strength lies in creating innovative, functional products that balance aesthetic appeal with manufacturing practicality. His design philosophy is deeply influenced by his multi-generational household experience—living with his wife, two sons, and mother has sharpened his innate empathy and observational skills, enabling him to anticipate how users interact with products in real-world scenarios. This user-first approach translates directly into thin wall part designs that are not only structurally sound and manufacturable but also intuitive and purposeful. When evaluating thin wall geometries, Jason considers ergonomics, fit and function, and lifecycle performance from the earliest concept stages. Outside the design studio, Jason finds creative balance through cooking, gaming, and relaxation, activities that fuel his innovative problem-solving abilities.

Shawn Monitor, Sr. Industrial Designer at Evok Polymers

Shawn Monitor

Sr. Industrial Designer

Shawn Monitor is Evok's visualization and prototyping virtuoso, bringing two decades of experience in translating complex thin wall concepts into tangible reality. His ability to communicate evolving design features through sophisticated mechanical and visual prototypes has been instrumental in some of the industry's most advanced seating and structural component projects. Shawn excels at building prototypes in diverse materials, enabling clients to validate thin wall designs before committing to production tooling—a capability that has dramatically reduced risk on large-scale projects. His technical toolkit includes photorealistic rendering in Otoy OctaneRender® and expert-level proficiency with Adobe Creative Cloud for technical diagrams and visual communication. Shawn's involvement in pre-molding design reviews has saved countless hours and dollars by identifying potential thin wall molding challenges early in the development cycle. He holds several patents and has conducted research spanning consumer products to biotech and medical applications. When not perfecting thin wall part prototypes, Shawn practices photography and enjoys the vibrant Twin Cities live music scene.

Daniel D. Hoyt, Ph.D., Business Development Manager at Evok Polymers

Daniel D. Hoyt, Ph.D.

Business Development Manager

Dr. Daniel Hoyt leads Evok's mission to transform traditional thin wall injection molding partnerships through innovative, lean collaboration models. His expertise in system and process design, combined with strategic partnership cultivation, positions Evok at the forefront of industry disruption. Daniel is passionate about building Partnership-Based Organizations that empower small and mid-sized businesses to compete through continuous improvement and mutual benefit. At Evok, he spearheads initiatives that challenge conventional approaches to thin wall part design, prototyping, tooling, and manufacturing—establishing new industry benchmarks for collaborative success. Daniel's vision extends beyond simply delivering parts; he's building a community centered on trust, transparency, and shared growth. His proficiency as a facilitator, public speaker, teacher, and coach makes him invaluable in helping clients navigate the complexities of thin wall component development. Under Daniel's leadership, Evok's clients gain not just a supplier, but a true partner invested in their long-term success and sustainable growth.

Natalie Weber, Operations Officer at Evok Polymers

Natalie Weber

Operations Officer – LIV

Natalie Weber represents the future of sustainable thin wall injection molding at Evok Polymers. As a dedicated apprentice in product design and management, she brings a fresh perspective that harmonizes creativity with environmental responsibility. Raised with an innate understanding of intangible design principles, Natalie recognizes the profound impact thin wall products can have on the planet—and she's committed to minimizing that footprint. Her education in sustainability, combined with hands-on mentorship from seasoned professionals including her father, drives her to infuse eco-consciousness into every facet of thin wall part development. Natalie investigates materials, manufacturing techniques, and emerging technologies with a critical eye toward ecological impact, always seeking ways to reduce waste, optimize material usage, and extend product lifecycles. Her work at Evok goes beyond creating functional thin wall components; she's actively shaping a future where high-performance injection molding seamlessly integrates with sustainability principles, leaving a positive legacy for generations to come.

Julie Young, Accounting and Finance Manager at Evok Polymers

Julie Young

Accounting and Finance Manager

Julie Young has been the financial backbone of Evok Polymers since its founding, ensuring the operational stability that enables the team to focus on thin wall molding excellence. As an experienced bookkeeper with meticulous attention to detail and thorough understanding of financial principles, Julie manages and maintains accurate financial records that support transparent pricing and customer trust. Her background in accounting, combined with a keen eye for numbers, allows her to organize transactions, reconcile accounts, and produce clear financial reports that inform strategic business decisions. Julie's proficiency in accounting software streamlines processes and ensures timely delivery of financial information, maintaining compliance with regulatory requirements while supporting the company's growth. Committed to professionalism and confidentiality, Julie provides reliable bookkeeping services that underpin Evok's financial health. Her dedication extends to ensuring all vendors are paid promptly—a reflection of the trust-based relationships that define Evok's approach to business partnerships.

Frequently Asked Questions

What is thin wall injection molding?

Thin wall injection molding is a specialized manufacturing process that produces plastic parts with wall thicknesses typically less than 1mm (often 0.5-0.8mm). This technique requires high injection speeds, specialized tooling, and optimized process parameters to completely fill thin cavities before the material solidifies. The result is lightweight, cost-effective components with excellent strength-to-weight ratios, commonly used in packaging, consumer electronics, and automotive applications.

What are the benefits of thin wall injection molding?

What materials work best for thin wall molding?

How fast are thin wall molding cycle times?

What design considerations are critical for thin wall parts?

How much does thin wall injection molding cost?

What quality control measures ensure thin wall part consistency?

Can you prototype thin wall parts before production tooling?

Have More Questions About Thin Wall Molding?

Our injection molding experts are ready to discuss your specific thin wall application and project requirements.

Certified Excellence

Awards and Recognition

Six Sigma Black Belt certification logo

Six Sigma Black Belt

Process excellence and quality optimization expertise

Allied Executives Business Leadership membership badge

Industry Leadership

Allied Executives Business Leadership member

Institute of Packaging Professionals certification logo

Packaging Professional

Institute of Packaging Professionals certification

Ready to Start Your Thin Wall Molding Project?

Share your project details and one of our injection molding specialists will contact you within 24 hours to discuss how we can optimize your thin wall components for speed, quality, and cost efficiency.

Contact Us Today

For immediate assistance, feel free to give us a direct call at +1 612-991-2001 You can also send us a quick email at