More than a year before the COVID-19 pandemic began, John Scrivener, a senior buyer from Nonin Medical, Inc., contacted Diversified Plastics, Inc. (DPI) to learn about the company’s capabilities and capacity as part of a supplier selection process. That was the start of a mutual partnership in the fight against COVID-19.

Nonin Medical’s Onyx® Fingertip Pulse Oximeter 

The Nonin supplier selection team was looking for a long-term partner to manufacture components for its Onyx® fingertip pulse oximeters and other potential products. Onyx fingertip oximeters are small and lightweight. They measure and display functional oxygen saturation of arterial hemoglobin (SpO2) and the pulse rate of a person. Clipped to a finger or toe, the device is used in hospitals, clinics, long-term care facilities, emergency medical services and home health settings. The first fingertip pulse oximeter on the market, Onyx has a durable hard plastic case designed to withstand vibration, shock, bumps and drops. Manufactured in black, blue and red, it has plastic channels that hold the batteries securely in place. In addition to Onyx fingertip oximeters, Nonin products are sold in 125 countries.

Supplier Selection Process

DPI was one of three plastic-injection molding companies that Nonin considered. Prior to starting the review process, Nonin’s team developed a vendor selection matrix. Key considerations included a robust 

quality control system and comprehensive validation process as well as a convenient location for easy collaboration. Each candidate company was asked to respond to a formal request for proposal and to provide a tour of their facilities.  

“We were transitioning from another plastic injection molder,” says Kristin Finberg, project manager at Nonin. “Searching for a new supplier was a big step for Nonin. We needed to be confident that the chosen vendor could meet our needs today and in the future. We ranked the companies based on the selection matrix criteria. DPI came out on top as a great fit.”

Tooling, Validation and a Rapid Surge in Demand 

After many years of use, the tools used to make the plastic-injection mold components for the Onyx fingertip pulse oximeters needed to be replaced. Moreover, there were a few design changes that Nonin wanted to integrate into the product. Alex Cromett, DPI’s engineering manager, along with Aliza Alverson, sales engineer for DPI, developed an action plan and schedule for Nonin. To ensure good communication and a smooth process, the technical teams from both companies held weekly
status meetings. 

While Nonin had the product design completed, they relied on DPI’s experienced team for tool design that would deliver maximum manufacturability and consistent, high-quality components. As part of its continuous improvement process, Nonin wanted to raise the bar for validation of the new tool. DPI delivered with an advanced validation protocol. Before the molds were made the teams reviewed the tool design. Once the tool was complete, prototypes were developed, and the first article inspection was successfully completed. 

“Just as we were getting close to going into production, COVID-19 happened,” explains Finberg. “That’s when Onyx product sales rapidly accelerated. Fortunately, we were already working with DPI to manufacture, decorate and assemble components of the Onyx fingertip pulse oximeters.”

Silent Hypoxia

An early warning symptom of COVID-19, silent hypoxia, is a condition in which oxygen levels in the tissue have dropped, but the individual has no signs that something is wrong. A pulse oximeter, or pulse ox, identifies patients with silent hypoxia, alerting physicians early that treatment may be indicated. Early treatment can keep COVID-19 patients off ventilators—and alive. Common and as simple to use as a thermometer, a pulse oximeter is an electronic device that measures pulse rate and the saturation level of oxygen carried in red blood cells.

Meeting Increased Demand

“When we started the review process, we couldn’t have imagined that demand for the product would increase as much as it has. This sales growth was a result of the product’s ability to help diagnose and monitor silent hypoxia in COVID-19 patients, and of our effective marketing strategy,” says Finberg. “The team at DPI was able to quickly assess the surge in volume and develop a plan, including additional tooling, to increase capacity. DPI has done an amazing job meeting our needs for increased production, and DPI was in the right place at the right time. Everything is going well.” 

Nonin’s marketing strategy regarding COVID-19, called All Together Now, is focused on serving the health care industry through education, recognition and thought leadership. Press coverage at NPR, in the Star Tribune, New York Times, CBS Morning Show, at Kare11 and others, generated as part of the campaign, contributed to the company’s recent success. To learn more about Nonin’s response to COVID-19, visit www.nonin.com/resources/covid-19/.

DPI is manufacturing everything that is plastic on the Onyx fingertip pulse oximeters, including the exterior or enclosure and the soft touch material that holds the finger. Some of the parts being manufactured require complex overmolding of different materials, which is one of DPI’s proficiencies. DPI also manages direct sourcing of lens components with one of Nonin’s other vendors. Additionally, the manufacturer is sourcing product decorating and completing some of the assembly. Once completed, the parts go back to Nonin to add the electronics, finish the assembly, and packaging.

A second wave of COVID-19 is anticipated in late fall or early winter. As a result, demand will continue globally for Nonin’s pulse oximeters. To maximize capacity, DPI is investing in additional presses. 

For more information about Diversified Plastics, Inc. visit divplast.com, call +1 763.424.2525.

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About Diversified Plastics, Inc.

Employee-owned Diversified Plastics, Inc. (DPI) is a custom plastic-injection molder and digital manufacturer of high-precision, close-tolerance parts and components for medical device, filtration, aerospace and a variety of other industrial markets. Founded in 1977, the company is a full-service contract manufacturer providing design for manufacturing assistance, additive manufacturing, mold construction and intricate molding as well as cleanroom assembly. In 2018, DPI purchased Pacific Plastics Injection Molding in Vista, Calif. DPI is ISO 9001:2015 and 13485:2003 certified, FDA registered, ITAR certified and UL registered. 

WeCutFoam, a company in Silicon Valley CA offering custom foam cutting, machining and prototyping services is expanding, and is now providing CNC wood machining services as well. The company being a subsidiary of Foamlinx LLC, manufacturer of foam cutting machinery is using its own line of CNC routers to mill and machine the material, on a table bed as large as 5ft by 10ft and up to 8 inches thick, all in one section. All types of wood can be machined, including plywood, melamine, MDF, particle boards and veneers.

The company typically produces custom signs, logo, letters, props, exhibits, displays, prototypes and composites. These products were mostly fabricated with foam materials, mostly Styrofoam and high-density Urethane foam, also known as tooling foam. Recently, the company received many request to produce wood products, hence the decision to expand and include CNC wood machining as well. Wood can be used to create vacuum forming molds, all types of furniture, custom oversized wooden planters, wood signs, décor, arts & crafts, architectural molds, crown moldings, panels, retails displays, trade show booths, instruments parts and tools, prototypes and many more as the applications of using wood is endless.

Customers can now use the company’s website to purchase custom large wooden planters, as long as 8ft or more that are hard to find at a local hardware store, they can buy decorative wall panels art made of stained plywood, mahogany, birch, cedar or cherry wood, they can order a decorative guitar, or inquire about any mold, composite or prototype they need.

WeCutFoam also combines wood machining with other types of materials such as foam, acrylics, Plexiglas, plastics, PVC, Sintra and composites. The CNC machining process, also known as subtractive manufacturing can also be combined with 3D printing additive manufacturing when the parts required are complicated and can benefit from combining these two processes. Projects can range from few inches to tens of feet as there is no limit to the size that can be fabricated. Any large pieces can be machined in sections, then glued together to form the desired shape or product.

Sigal Barnea, WeCutFoam Co-Owner stated “This is a great addition to the services we are already providing to our customers, and we are always happy to be able to grant any new wishes, as our customers are the ones guiding us, we owe them our success”. Sigal continues to say that especially now, during Covid-19 situation where there is another reality out there, with non-existent events and exhibits (which were a big part of our end users), we are thrilled to be able to expand and adjust ourselves to new markets.

While Wood might be more expensive than foam and much heavier, some products require the characteristics of wood rather than anything else. For example, it can be painted with a semitransparent stain or color to still show the material finish and shape. The choices of the material is also very broad and includes many types of wood to choose from that might add a high-value to the product.

WeCutFoam, established in Silicon Valley, CA since 2001, specializes in custom cutting shapes and products out of foam, wood, plastics and light metals. The company creates prototypes, molds, architectural shapes, props, sculptures, logos, signs, letters, museum exhibits, Trade Show displays and more. 3D printing, hard coating, hot wire cutting and vinyl printing services are also provided. Projects range from few inches up to large 3D realistic full scale cars, trucks, boats, airplanes and props. To learn more visit http://www.wecutfoam.com call 408-454-6163 or send your inquiry to This email address is being protected from spambots. You need JavaScript enabled to view it.

MINNEAPOLIS—Diversified Plastics, Inc. (DPI), custom plastic-injection molder and additive manufacturer of high-precision components, has released a new white paper titled Design for Manufacturing Yields Better Profits and Shortens Time to Market. This white paper explores how parts intended for plastic-injection molding, simple or complex, can greatly benefit from optimizations found during the design for manufacturing (DfM) process.

To download this white paper, visit www.divplast.com/design-for-manufacturing/. 

“Working with an experienced plastic-injection molding and tooling production partner during the design phase can streamline the process,” says Mark Gremmels, director of operations of Diversified Plastics, Inc. “DfM helps avoid costly pitfalls and time-consuming iterations, allowing for a quicker time to market.”

This white paper provides information about a few key DfM topics that can offer immediate benefits, including material selection, wall thickness, corner radii, draft angles and mold-flow analysis. It summarizes performance requirement considerations for selecting the right material for a part as well as design techniques to avoid warping, and cosmetic issues. Additionally, it discusses structural strength benefits of optimized wall transitions with sufficient radii. You will also gain an understanding of how mold-flow analysis, performed by subject-matter experts, can proactively address manufacturability problem areas.

Download the white paper by visiting www.divplast.com/design-for-manufacturing/ or for more information, call +1 763.424.2525

About Diversified Plastics, Inc.

Employee-owned Diversified Plastics, Inc. (DPI) is a custom plastic-injection molder and digital manufacturer of high-precision, close-tolerance parts and components for medical-device, filtration, aerospace and a variety of other industrial markets. Founded in 1977, the company is a full-service contract manufacturer providing design for manufacturing assistance, additive manufacturing, mold construction and intricate molding as well as cleanroom assembly. In 2018, DPI joined the Carbon Production Network. DPI is ISO 9001:2015 and 13485:2016 certified, FDA registered, ITAR certified and UL registered.  www.divplast.com 

Diversified Plastics, Inc.

8617 Xylon Court North

Minneapolis, MN 55445

+1 763.424.2525

www.divplast.com/design-for-manufacturing/

MINNEAPOLIS—Diversified Plastics, Inc. (DPI), a custom plastic-injection molder and digital manufacturer of high-precision thermoplastic components, was named winner of the 2019 Plastics News Excellence in Employee Relations Award. According to Plastic News, the Excellence in Employee Relations Award is given to companies that excel in this individual category of the Processor of the Year Award. Winners were announced February 26 at the annual Plastic News Executive Forum in Naples, Fla.

Citing their industry-wide reputation as an employee-first company, Diversified Plastics, Inc. CEO Kevin Hogan said, “I am privileged to receive this award on behalf of all DPI's outstanding employee owners. DPI has a rich history of employee excellence. We were founded 42 years ago by a group of 13 employees, known as the baker's dozen. As we look toward the future, we honor our legacy, and make sure there's always a plan for increasing value for the employee owners."

Employee ownership began with founder and former CEO James "Jim" Dow who met with potential buyers of DPI in 2011. Concerned that the company culture and progress would be negatively impacted in the hands of new ownership, Dow created the employee stock ownership plan (ESOP) for DPI. 

"We all thought the company was going to be sold," said Janel Rosine, sales engineer and customer service representative at DPI. "And we worried about our jobs. Finding out that Jim sold the company to us gave us all a stake in the company."

"The fact that DPI is an ESOP means a great deal," said Gary LaTraille, director of quality assurance at DPI, "and this is also a great place to work.” There's a jovial attitude, and everybody loves their job."

The employee-owners have a lot to love about their company. DPI was recently a finalist in the Association for Corporate Growth's BOLD Awards and received the 2015 Company of the Year Award from the Minnesota/Dakota Chapter of the ESOP Association. 

DPI realized exceptional revenue growth in 2019. In addition, the ESOP stock price has climbed 72 percent over three years, with revenue per employee up 12.4 percent. The average tenure of DPI employees is an impressive 12 years. Focused on rapid, profitable growth, DPI is an industry-leading producer in a wide variety of markets, including medical devices, water filtration, industrial components and more. 

Employee relations and revenue are not the only areas where the company excels. In 2018, DPI added Acceleration Station™ services, which utilize Carbon® Digital Light Synthesis™ (DLS™) additive manufacturing. This technology is 100 times faster than traditional additive methods. The Carbon DLS process produces consistent isotropic mechanical properties, creating parts that are durable for end-use applications. The result is a rapid go-to-market strategy, enabling customer success while maintaining precision specification, performance and safety standards. DPI was the first plastic-injection molder in the region offering Carbon additive technology. 

As its first strategic acquisition, DPI purchased Pacific Plastics Injection Molding (PPIM) of Vista, Calif., which is one of the geographic hubs for the medical device industry. The synergies between the two companies have benefited customers and employees.

For more information about Diversified Plastics, Inc. visit www.divplast.com, call 

+1 763.424.2525 or email This email address is being protected from spambots. You need JavaScript enabled to view it..