Contract Manufacturing and assembly
Streamline Your Production with Our Comprehensive Contract Manufacturing and Assembly
Blue Ridge’s contract manufacturing and assembly services offer a seamless extension to our custom injection molding capabilities, ensuring your products are fully prepared for the market—without juggling multiple vendors. We focus on process enhancements, lean workflows, and a family-like culture that treats every assembly or packaging task with meticulous care. As a trusted partner, we go beyond injection molding to deliver tailored solutions that optimize product management, streamline operations, and strengthen long-term relationships.
Key Capabilities
Ultrasonic Welding: Securely fuses plastic components, creating robust bonds without adhesives.
Insert Installation: Embeds metal or plastic inserts to reinforce threaded holes or attachment points.
Mechanical Assembly: Combines multiple molded and purchased components into a complete unit.
Functional Testing: Ensures each product meets operational requirements before distribution.
Point-of-sale Packaging: Preps items for immediate retail placement, maintaining a professional presentation.
Shrink Wrapping: Offers a protective, tamper-evident layer around individual products or grouped sets.
Anti-theft Tag Placement: Integrates security elements essential for retail environments.
Labeling: Delivers a polished finish with accurate, brand-consistent labeling options.
Our Approach
Integrated Post-Molding Solutions
Once parts emerge from our 50–1,000 ton presses, they can move directly into assembly and packaging stations under the same roof. This single-source approach eliminates unnecessary shipping steps or coordinating with outside contractors, saving you time and reducing handling risks.
Precision Assembly and Testing
Depending on your project’s complexity, our team can perform insert installation, ultrasonic welding, and mechanical assembly to create a fully functional unit. We also conduct functional testing to confirm product performance—whether it’s a simple fit-test or more advanced operational checks.
Packaging and Security
After assembly, products can be readied for their final destination through point-of-sale packaging, shrink wrapping, anti-theft tag placement, and labeling. Each step is documented and monitored to uphold our 95% or higher acceptance rate and protect product integrity.
Sourcing and project Management
We provide seamless inventory management with real-time dashboards that track component needs, ensuring timely orders and uninterrupted production, especially for assembly products. Our just-in-time inventory support allows us to build and store products, giving customers flexibility and efficiency in their supply chain.
Real-world Applications
-
![]()
Retail-ready Consumer Products
Combine injection-molded components, insert packing labels, and shrink-wrap final units for direct shipment to store shelves.
-
![]()
Industry-specific Products
Insert bushings and fasteners into injection-molded housings, then perform ultrasonic welding to create a robust, vibration-resistant enclosure.
-
![]()
Reliable Product Quality
Conduct functional tests on small components, ensuring they meet required tolerances before pad printing and packaging for distribution.
Our Other Capabilities
-
![]()
Engineering Support
Data-Informed Design and Process Optimization
Our engineering team applies Design for Manufacturability principles, mold flow analysis, and careful material selection to ensure your parts are production-ready before tooling begins. By using industry-leading software and real-time data insights, we proactively refine designs to reduce cost, shorten lead times, and maintain exceptional quality. It’s a collaborative, ingenuity-driven approach that blends your product vision with our decades of expertise.
-
![HP Jet Fusion 540 3D Printing and Prototyping Machine]()
3D Printing and Prototyping
Validate and Refine Before Full Production
Transform ideas into tangible prototypes in days, not weeks. Our 3D printing and prototyping services let you quickly test form, fit, and function—so you can spot and fix issues before committing to high-volume tooling. Whether it’s an ergonomic handle, electronics enclosure, or a pilot run for market feedback, our rapid prototyping process collapses multiple design cycles into one swift, data-driven workflow.
-
![Custom Injection Molding Machine]()
Custom Injection Molding
Flexible, High-Quality Production
Equipped with 24 presses ranging from 50 to 1,000 tons, Blue Ridge handles everything from low-volume trials to large-scale runs around the clock. We hold ISO 9001:2015 certification and uphold IATF16949 MAQMSR compliance standards—ensuring automotive-grade quality and precision. With 6-axis robotic automation, engineering software support, and our 24/7 operations, we deliver reliable parts on time, every time.
-
![Cobot robot being used during injection molding manufacturing process]()
Automated Manufacturing Solutions
Robotic Precision & Data-Driven Throughput
Our automated manufacturing processes take efficiency to the next level. By integrating 6-axis robotics, advanced sensors, and real-time data monitoring, we minimize manual labor, reduce scrap, and keep production lines moving smoothly. This future-forward setup is ideal for businesses aiming to scale fast or accommodate sudden demand spikes—all while preserving consistent quality in every cycle.
-
![]()
Plastics Decorating
Hot Stamping and Pad Printing for a Polished Finish
Enhance brand identity and final product appeal with our plastics decorating services. We offer hot stamping for metallic or high-contrast finishes and pad printing for multi-color, detailed graphics—ideal for consumer goods, medical device labeling, and more. Each decorative step is managed under the same roof as our molding processes, cutting down on external logistics and lead times.
-
![Blue Ridge's Fulfillment and Inventory Warehouse]()
Fulfillment and Warehousing
Min/Max Inventory & On-Demand Shipping
From min/max inventory management to pick-and-pack fulfillment, our fulfillment and warehousing capabilities are designed to keep your products moving. Strategically located on I-81 in Virginia, we can ship orders in under 24 hours via UPS, FedEx, or LTL truckloads. This one-stop model avoids extra handoffs and ensures your supply chain remains efficient, flexible, and cost effective.
Take Your Product from Mold to Market
Ready to eliminate supply chain complexity and bring your products to market faster? Blue Ridge’s contract manufacturing and assembly services ensure every part of the post-molding process is handled with the same ingenuity and attention to detail that define our injection molding operations. Contact us or visit our request a quote page to discover how we can simplify your production and enhance your bottom line.