Manufacturing & Assembly

In addition to our management services for products and corporations we have a wide range of manufacturing and assembly solutions at our disposal for our clients, very few possibilities are beyond our reach.

As a company, we began in manufacturing and it is what we love to do. Whether it’s helping to set up your manufacturing capabilities or the need for manufacturing space, we can help. Operating out of 48,000 square feet facilities in Lebanon, IL we offer custom manufacturing solutions. We make it easy for one stop manufacturing.

Our greatest asset is our employees who take great pride in their work making sure that no matter what product they are making it is made with the highest level of quality.  Our expert staff will assist you with design, tooling, customization, and material selection to provide you with a creative solution for your project.

Contact us today to set your custom solution.


Die Cutting

Die CuttingA printing process where we cut an object out of a sheet of paper using a steel rule die. The die has cutting rules that when applied to the sheet of paper with the right amount of pressure will cut out the desired object. This kind of process is used to produce door hangers, pocket folders and tabs to name a few.

Custom Product Innovations is one of the few St. Louis area printers that does die cutting in house. We do this to control costs for our clients as well as control quality and often, faster turn around times for our clients.


Dip Molding

Dip Molding

Offering a wide range of capabilities in itself our dip molding group Custom Coating Innovations can make it happen for you.

Custom Coating Innovations specializes in molding and Coating Solutions. Molding is an effective alternative to the typical plastics process for the molding of covers, grips, handles various other applications.

Molded and Coated solutions can offer an attractive alternative to painting and/or other standardize methods of sealing and protecting. Plastisol, Latex and other rubber based material has come a long way over the past years and more and more companies are looking at this based material as options to not only protect, but to increase product longevity and minimizing extensive damaging to equipment.



RF (Radio Frequency) Welding

RF Welding

Certain plastics with chemical dipoles, such as PVC, polyamides and acetates can be heated with high frequency electromagnetic waves. High frequency welding uses this property to soften the plastics for joining. The heating can be localized, and the process can be continuous. Also known as Dielectric Sealing, R.F. (Radio Frequency) Heat Sealing.

Radio frequency welding is a very mature technology that has been around since the 1940s. Two pieces of material are placed on a table press that applies pressure to both surface areas. Dies are used to direct the welding process. When the press comes together, high frequency waves are passed through the small area between the die and the table where the weld takes place. This RF field causes the molecules in certain materials to move and get hot, and the combination of this heat under pressure causes the weld to take the shape of the die. This type of welding is used to connect polymer films used in a variety of industries where a strong consistent leak-proof seal is required. In the fabrics industry, RF is most often used to weld PVC and polyurethane (PU) coated fabrics. This is a very consistent method of welding.

The most common materials used in RF welding are PVC and polyurethane. It is also possible to weld other polymers such as Nylon, PET, PEVA, EVA and some ABS plastics.

(Information used from Wikipedia)


Impulse Welding

Impulse Welding

With multiple impulse welding stations and set ups we can weld everything from PVC to Fluropolymers.

Impulse welding is a variation of hot bar welding where the heated bar is replaced with a thin Nichrome wire positioned behind a PTFE coating or film. During the heating cycle an electric current is passed along the wire, resulting in rapid heating. At the conclusion of the heating cycle, the current is switched off and the wire cools rapidly due to its low thermal mass. The films being joined remain under pressure for the duration of the cooling cycle. In this way, the parts being welded experience a well-controlled heating and cooling regime, while still being held under pressure.

(Information used from TWI)


Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or “film” when referring to thinner gauges and certain material types, is heated in an oven to a high-enough temperature that permits it to be stretched into or onto a mold and cooled to a finished shape. We often use this method, both to create sample and prototype parts for a wide variety of clients and then create en mass.

(Information used from Wikipedia)



Our sewing capabilities allows us to design everything from prototyping to large production runs with many different types of fabric. We have manufactured everything from military and tactical pouches, to bedding and hammocks, to fitness equipment.  Sewing is one of our most diverse operations.