From Product Concept to Finished Assembly
Integrated capabilities across product development, mould design, injection moulding, 2K moulding, assembly, and packaging — helping move products efficiently from concept to completion under one roof in Pune, India.
From Concept to Completion
From product concept and mould development to moulding, assembly and final preparation, FD Group brings together the capabilities required to move products from design to completion.
01 — PRODUCT DESIGN & DEVELOPMENT
Translating product concepts into practical designs prepared for manufacturing with DFM risk assessments and 3D modeling.
Our design engineering team collaborates closely with OEMs and product innovators at the earliest stages. We review part geometry, wall thickness uniformity, draft angles, rib structures, and parting lines to eliminate sink marks, warpage, and costly re-tooling before steel is cut.
- 3D Solid CAD Modeling (STEP, IGES, Parasolid formats)
- DFM (Design for Manufacturability) Risk Analysis
- Mold Flow Simulation (Filling, Shrinkage & Warpage)
- Part Geometry & Wall Thickness Optimization
- Engineering Polymer Material Selection Guidance
02 — MOULD DESIGN & MANUFACTURING
Developing production-ready mould solutions aligned with component requirements and manufacturing needs in our precision toolroom.
FIFO Industries operates an advanced in-house precision mould making toolroom in Bhosari MIDC, Pune. From prototype bridge moulds to multi-cavity hardened steel production dies, our tools are built for high repeatability, rapid cycle times, and long tool life.
- 2-Plate, 3-Plate, Hot Runner & Cold Runner Tooling
- 2K / Multi-Component & Unscrewing Mould Tooling
- High-Speed CNC VMC Machining & Precision Wire Cut EDM
- Hardened Core/Cavity Tool Steels (P20, H13, 1.2316, Stavax)
- 100% In-House Tool Maintenance & Die Preservation
03 — INJECTION MOULDING
Manufacturing precision components through controlled injection moulding processes across 60T to 650T machine capacities.
FIFO Polymers runs modern, energy-efficient microprocessor-controlled injection moulding presses. With closed-loop process monitoring, mould temperature controllers, and automated dehumidified hopper drying, we ensure tight dimensional consistency across both commodity and advanced engineering polymers.
- 60T to 650T Modern Injection Moulding Fleet
- Engineering Polymers (ABS, PA6/PA66, PC, POM, PBT, PP)
- Tight Dimensional Tolerance Control (±0.02mm)
- Servo-Hydraulic Efficiency & Closed-Loop Parameter Control
- Centralized Dehumidified Resin Drying & Loading
04 — 2K / TWO-COMPONENT MOULDING
Combining two materials or components within a single moulding process where the application requires integrated functionality.
Our specialized 2K moulding machines inject two different polymers (e.g. rigid structural substrate like PP/PA/PC and soft-touch elastomer like TPE/TPU) within a single automated cycle. This delivers a permanent molecular chemical bond, eliminating secondary adhesive gluing, manual fasteners, and leak paths.
- Multi-Material Molecular Chemical & Mechanical Adhesion
- Soft-Touch Overmolding (Ergonomic Grips, Handles, Knobs)
- Integrated Hermetic Sealing Gaskets & Anti-Vibration Dampers
- Dual-Color Aesthetic Styling & Non-Wearing Identification
- 100% Elimination of Secondary Manual Assembly Steps
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05 — ASSEMBLY & INTEGRATION
Bringing manufactured components together through an organized assembly process to create completed product assemblies.
FD Group operates a dedicated, dust-controlled assembly floor equipped with custom-built jigs and checking fixtures manufactured by FIFO Engineering. We handle everything from sub-component joining to fully tested, serialized and validated turnkey products.
- Dedicated Assembly Cells & Multi-Part Sub-Assemblies
- Ultrasonic Welding, Thermal Heat Staking & Inserts
- Mechanical Fastening & Torque-Controlled Assembly Lines
- Custom Poka-Yoke Assembly Jigs & Go/No-Go Gauges
- Functional Verification, Leak Testing & Fitment Checks
06 — PACKAGING & FINAL PREPARATION
Preparing completed products for handling, protection and delivery through appropriate packaging processes.
Every manufactured batch undergoes final quality audits, protective packaging, and lot traceability tagging before leaving our facility. Whether shipping to domestic assembly lines in Pune or exporting in sea-freight containers globally, parts arrive protected and ready for immediate deployment.
- Custom Export Packing (Seaworthy Crates & VCI Protection)
- Returnable Crates, ESD Packaging & Custom Trays
- Complete Barcoding, QR Coding & Batch Lot Traceability
- Clean Polybagging, Blister Packing & Retail Box Packaging
- Coordinated Direct-to-Line Logistics for Global OEMs
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2K / Two-Component Injection Moulding
Combining two materials or colors within a single automated moulding cycle — delivering seamless multi-material bonding, integrated sealing gaskets, and ergonomic soft-touch surfaces without secondary assembly.
Molecular Material Bond
True chemical adhesion between rigid polymer substrates (PP, PA, PC, ABS) and soft-touch elastomers (TPE, TPU), eliminating leak paths.
Zero Secondary Assembly
Parts emerge completely integrated from the mould, eliminating adhesive gluing, manual fasteners, and secondary labor costs.
Hermetic Sealing & Dampers
Moulding elastomeric gaskets and vibration dampening zones directly onto structural housings for superior IP-rated protection.
Dual-Color Aesthetics
Distinctive multi-color branding, durable non-wearing labels, and clear-window indicator lenses integrated into one part.
Dedicated Assembly & Integration
FD Group operates a dedicated, organized assembly section that enables smooth transition from moulded components directly into finished, multi-part assemblies — eliminating multi-vendor handoffs and secondary logistics overhead.
Sub & Final Assembly
Mechanical assembly of plastic components, fasteners, inserts, and sub-assemblies according to precise customer specifications.
In-House Custom Jigs
Dedicated assembly fixtures, holding tools, and checking gauges designed and manufactured in-house by FIFO Engineering.
Ultrasonic Joining
Ultrasonic welding, heat staking, and precision insert insertion for robust multi-material component bonding.
In-Process Inspection
Fitment checks, torque validation, and visual cosmetic inspection at each step of the assembly workflow.
Built for Scale: From Pilot Runs to High-Volume Production
Our infrastructure is engineered to adapt to every phase of your product lifecycle — supporting prototype validation, bridge production, and high-volume mass manufacturing without sacrificing precision.
Prototype & Testing
Rapid tooling and prototype sampling to validate part geometry, fitment, and functional requirements before committing to production tooling.
Bridge Production
Low-to-medium volume manufacturing for market testing, pilot runs, and specialized equipment while tooling amortisation is optimized.
Commercial Batch Runs
Hardened steel multi-cavity tooling and scheduled batch runs designed for steady commercial supply with tight quality control and batch documentation.
Mass Production
High-volume multi-cavity and hot-runner tooling running on automated cycles with robotic pickers, maximizing throughput and minimizing per-part cost.
Modern Manufacturing Infrastructure
Operating with modern machinery across injection moulding, precision CNC tool room machining, and automated secondary equipment to ensure high process stability and repeatable tolerances.
Injection Moulding Fleet
Process-controlled injection moulding machines with microprocessor controls, auxiliary dehumidified hopper dryers, and mould temperature controllers.
- Clamping Force: 60T – 650T
- Moulding Types: Standard, 2K, Insert
- Shot Capacities: 0.5g to 2,500g
In-House Tool Room
High-speed Vertical Machining Centres (VMC), precision EDM spark erosion, and CNC wire cutting for micron-accurate core and cavity fabrication.
- Machining: CNC VMC, EDM, Wire Cut
- Tool Types: 2-Plate, 3-Plate, 2K, Hot Runner
- Maintenance: 100% In-House Tooling Bay
Design & Metrology Lab
Advanced CAD/CAM design workstations running licensed software paired with Coordinate Measuring Machines (CMM) for precision inspection.
- CAD/CAM: NX, VISI, SolidWorks, AutoCAD
- Inspection: CMM & Precision Gauges
- Quality Cert: ISO 9001:2015 System
Clean & Organized Manufacturing Environment
A clean, disciplined, and systematically organized shop floor is essential for precision moulding and optical/cosmetic component quality. Our facility in Bhosari MIDC, Pune follows strict 5S housekeeping and material controls.
Controlled Material Handling
Dedicated resin storage, dehumidified drying hoppers, and contamination-free material conveying to molding machines.
5S Workplace Discipline
Structured 5S standards across production aisles, tool staging zones, and component handling cells.
Enclosed Assembly Area
Dust-controlled and organized post-moulding assembly spaces with dedicated inspection stations.
Systematic Tool Storage
Organized mould preservation and storage area ensuring tooling integrity between production campaigns.
ISO Documentation & Production Records
Comprehensive quality documentation, statistical process tracking, and full material traceability maintained for every production run to satisfy demanding OEM and international audit requirements.
ISO 9001:2015 System
Certified quality management system governing all processes from raw material intake to final dispatch.
CMM Dimensional Reports
First Article Inspection Reports (FAIR / PPAP) and CMM dimensional verification for critical tolerances.
SPC & Cpk Tracking
Statistical Process Control (SPC) and capability tracking ensuring dimensional stability across batches.
Full Lot Traceability
End-to-end traceability linking raw material test certificates (MTC), machine parameters, and dispatch batches.
Standards & Compliance
The Complete Manufacturing Journey
From initial concept drawing to final packaged product delivered at your doorstep — single-source accountability under one roof.
Zero Multi-Vendor Delays
Eliminate inter-vendor finger pointing between toolmakers, moulders, and assembly houses. Every stage is managed in-house.
Reduced Landed Costs
Avoid multiple transit freight costs, duplicated packaging cycles, and handling markups with an integrated manufacturing model.
Single Accountability
One dedicated engineering partner responsible for tooling precision, moulding tolerances, assembly fitment, and final dispatch.
Have a Product in Mind? Let's Build It Together.
Discuss your component drawing, concept, or tooling requirement with FD Group's senior engineers. We provide detailed DFM feedback, transparent tooling quotations, and end-to-end production roadmaps.
Frequently Asked Questions
Everything you need to know about partnering with FD Group for contract manufacturing, tooling, 2K moulding, and assembly.