Domestic Collaboration Yields Efficiency and Budget Gains For Innovative Tooling Project

Pyramid Molding Group (PMG), a domestic mold builder and plastic injection molder based in Rockford, Illinois, partnered with Lettuce Grow to develop tooling for the second generation of its innovative hydroponic plant stand. This project involved collaboration on the technical considerations, cost management strategies and project management approaches necessary to successfully complete the project — from designing and manufacturing the tooling to molding and adjusting the tooling for the final parts.

Lettuce Grow, best known for its Hydroponic Farmstand, set out to develop a smaller version called “The Nook” suitable for homes and apartments. Originally, the company planned to get the tooling overseas but ultimately decided to keep the project within the United States. This choice was driven by the company realizing it could stay within its budget and take advantage of a seamless, all-in-one solution provided by PMG.

“We decided to keep the project in the United States to support local sourcing and strengthen community ties, aligning with our commitment to sustainability and local economies. By staying in the United States, we also avoided sending staff to China for tool validation and adjustments,” says Jacob Pechenik, CEO of Lettuce Grow.

Tooling Considerations

PMG collaborated with Lettuce Grow to identify the most cost-effective tooling options while ensuring the product's design and functionality remained intact. Since the design was already largely determined, PMG focused on making tweaks to reduce tooling costs while maintaining functionality. 

PMG’s in-house engineering team carefully evaluated mold gate types and design options to ensure optimal part quality and functionality. “We evaluated various gate locations for the different parts to balance flow, minimize defects and enhance the overall aesthetics of the final product. The choice of gate types was critical in achieving efficient filling and maintaining the structural integrity of the components,” Raymond Gibler II, PMG Operations Manager, says. 

Lettuce Grow was also concerned with fit and function and wanted to ensure optimal water flow for plant growth in the Nook. To further refine the mold design, PMG used Moldex3D to conduct fill analysis on parts that incorporated a cold sprue. These analyses provided insights into the flow patterns and potential issues, enabling PMG to make informed adjustments to the design and ensure uniform filling and minimal warpage.

Design for Manufacturability

Throughout the design phase, PMG’s engineering team provided valuable input based on moldability considerations. “We implemented Design for Manufacturability (DFM) principles to streamline the production process. By creating detailed design concepts for all tools, we established a solid road map for our designers,” says Gibler.  

Certain parts required a more in-depth DFM approach due to their complexity, ensuring that the designs were optimized for efficient and cost-effective manufacturing. PMG worked in partnership with Lettuce Grow to create revisions to the design to gain functionality for the overall product.

Lettuce Grow also prioritized minimizing waste, so PMG used post-consumer materials. They also assisted with product packaging development, as PMG would ultimately assemble and ship the finished Nook directly to consumers. 

“Since we were ultimately packaging and shipping the product direct-to-consumer, we collaborated with Lettuce Grow to make sure we used as little packaging as possible for sustainability while still providing safety for the product,” says Gibler.

Lettuce Grow chose to keep the project within the United States, recognizing the advantages of working with a local partner including quality control, shorter lead times, reduced transportation costs and a simplified supply chain. 

Project Management

To manage the project, PMG held frequent design reviews. Lettuce Grow was assigned a dedicated point of contact at PMG to oversee the tool build, with bi-weekly meetings scheduled to discuss updates on DFMs and part design. 

During the early stages of the project, frequent design reviews were conducted to discuss part changes and moldability concerns. These collaborative sessions ensured both teams were aligned on design objectives and enabled PMG to address potential issues proactively. 

Improved communication led to better timing, convenient meetings and swift issue resolution. “We operated as a one-stop shop and handled all tooling-related aspects as part of our project management,” says Gibler.

Regular touch-base meetings led to the successful production of the tooling. Lettuce Grow invested time upfront to ensure the product met its requirements, resulting in minimal engineering changes after the T0 sample.

The collaboration between Pyramid Molding Group and Lettuce Grow on the Nook hydroponic plant stand succeeded in bringing a complex assembly to life, reflecting the strength of the partnership and the quality of work that can be achieved with the right technical expertise, innovative problem-solving capabilities and effective project management.

“PMG played a crucial role in our product development by being flexible and understanding. They accommodated numerous design iterations, which enabled us to refine our product to meet the highest standards while keeping the manufacturing in the United States.,” says Pechenik.