Problem-Solving Powers MPP's Growth

Tell us about MPP's journey and current setup.

Gabe Meldrum, Program Manager, MPP: We started in 1990 with a simple goal: build precise, quality molds. Today, we work out of a 26,650-square-foot facility with 26 team members. Our mold shop runs with 22 skilled craftspeople and we have two people dedicated to our molding operations. The average age of our team is 47, but we're keeping an eye on the future with two active apprentices.

Our growth has been steady, marked by smart investments in technology and equipment. The 2021 expansion into molding was a game-changer. Having molding right next to our mold shop means we can get perfect parts to customers faster than ever.

What's your sweet spot in the market?

Meldrum: We shine with complex projects — two-shot specialties, tight-tolerance work and multiaction tooling. We handle both prototype and production molds, plus we’ve expanded into high- and low-volume molding. Our work spans defense, automotive, consumer goods and powertrain applications. We’re comfortable working with both engineering and commodity resins.

The molding facility isn't just for sampling, we can handle production runs too. Everything’s under one roof, from initial prototype designs through to final production molding. This setup gives us total control over quality and timing.

What sets MPP apart from other shops?

Meldrum: It’s a mix of experience and fresh perspectives. Our team has over 100 years of combined experience, but a third of our crew is under 40. We’ve built a culture of respect and kindness that makes people want to stick around. Plus, we invest in our team’s education and training. In our small community, word spreads fast about workplace culture, and our retention rates speak for themselves.

We also take on projects others might pass up. For example, we recently brought an old eight-cavity stack mold for flower pots back to life. It was 36 years old, rusty, with no 3D data available. After some detective work and repairs, we got six of the eight cavities running again. That kind of problem-solving mindset really connects with customers.

Any recent tech upgrades that changed your game?

Meldrum: Our new YCM CX4 five-axis CNC has been transformative. It has a 14,000-rpm spindle, Renishaw probe for precise fixture offsets, through-the-tool coolant and a 40-position toolchanger. The full five-axis capability means we can finish slides completely on one machine now. This work used to need multiple setups and EDM operations. The through-tool coolant and ability to reach all five sides of a workpiece really sets this machine apart.

How about changes to your business approach?

Meldrum: The big one is our new molding operation. We've installed three new Haitian injection molding machines — two Zeres series (101 and 337 ton) and a 528-ton MARS III with all the supporting equipment, including dryers, hot runners, valve gate controls and chillers.

We’re ISO 9001:2015 and IATF-16949:2016 certified, with a quality engineer and process engineer who know their stuff. They’re trained in Automotive Industry Action Group (AIAG), Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP). Plus, our process engineer is an RJG-certified master molder.

In 2022, we obtained ITAR registration and registered with the DOD, opening doors for more defense work. This fits perfectly with our expansion plans and capabilities.

It’s a mix of experience and fresh perspectives that sets up apart. Our team has over 100 years of combined experience, but a third of our crew is under 40.

Looking ahead 3-5 years, where’s MPP headed?

Meldrum: With reshoring picking up steam, we expect our molding business to grow. Having molding capabilities in-house lets us fine-tune processes faster than shops that have to ship tools out for trials. Once we nail down the process, we can give customers exact parameters so they’re making perfect parts from day one in their own facilities.

We’ve added 8,000 square feet of climate-controlled molding space and we’re planning to add a clean room for medical device work. We’re also pushing to boost our automation for better lights-out manufacturing. Our machines already use tools and electrode changers, with System 3R robots tending to our electrode-cutting machines. We’re looking at adding conveyor systems to automate the molding side and we’re eyeing the Hermle HS-Flex cell. We like that the machine and robot come from the same manufacturer.

How are you handling the skilled labor challenge?

Meldrum: We run a DOL-registered apprenticeship program we developed ourselves. It’s a four-year commitment — 8,000 hours of hands-on work plus 592 hours of related instruction. Our apprentices learn everything from basic measuring to CAD systems. We’ve had five graduates so far, with two current apprentices. We try to keep two apprentices in the pipeline every four years, often promoting our shopfloor helpers into the program. It’s a great way to bring along someone who’s already proven they’re eager to learn.

What's the most interesting project you've tackled lately?

Meldrum: We built some fascinating two-shot production molds for a window lift system using a spinning plate design. Instead of a rotating platen, these use a servomotor to lift and spin plates which present cores to different cavities. Getting perfect alignment in the custom mold base was critical. It had to be spot-on for the tool to function properly.

We also made tooling for a plastic coolant hub that won an SPE Automotive Innovation Award in the powertrain category. It was a laser-welded hub made from glass-filled PA66 which cut connections by 30% and saved serious assembly time. The design reduced packaging space by 50%, while eliminating 29 tube insertions and six tube-forming processes. Getting those parts flat enough for welding required significant collaboration on mold flow analysis and cooling strategy.

How do you plan to grow these new capabilities?

Meldrum: Our sales strategy for molding follows the same philosophy that’s worked for our moldmaking: deliver top service and hit your deadlines. We’re getting our name out there through trade shows and regular social media posts which showcase our strengths. Our experience shows that if you take care of customers, they’ll take care of you.