An ISO 9001:2008 Company

Why OEMs Work With BDI

30+ years of Successful Partnerships and Counting

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For 30+ years BDI has built lasting relationships with our OEM Partners. In that time not a single one of them has left. Why? It’s the simple things really.

  • Things like being on-time, every time!
  • Being on spec with laser-sharp focus on quality.
  • It’s the relationship that we have built together, the fact that BDI has focused itself on delivering success in the business of our Partners.
  • Being certified for the most stringent industry quality systems.
  • It’s about the comprehensive list of materials we work with.
  • It’s about going the extra mile.
  • And most of all, it is because: we all want to work together; we have our client’s best interests at heart!

Our Manufacturing Capabilities

Large manufacturing footprint with state-of-the-art rotational molding equipment having latest computerized process controls.

  • Automated trimming equipment including CNC Routers.
  • CAD systems for product design, CAE and FEA simulations.
  • Single-piece joint-less molded part sizes ranging from mere 0.1 meters to 4.1 meters in diagonal length.
  • Complete in-house mold manufacturing and maintenance capabilities including CNC/VMC machines.
  • Metal to Plastic conversion, Wood to Plastic conversion.
  • A range of shapes, from simple to intricate.
  • Custom colored products.
  • Complete assemblies per customer specifications.
  • Molding experience of a wide range of materials from Polyethylene to polyamides and polypropylenes.
  • XLPE fuel tank specialists.
  • In-mold polyethylene foam layers.
  • Post-mold polyurethane foam filling.
  • Dependable PIAT monitoring and controlling system.
  • Extrusion and Pulverizing capabilities.
  • In-mold inserts, labels and graphics, cut-outs, foams.
  • Detailed and reliable product testing, functional conformance and validation systems in-house.
  • Fully equipped and staffed material testing laboratory.
  • Highly evolved Enterprise Resource Planning (ERP) systems from SAP custom-built and best suited to roto-molding needs. Our systems effectively manage customer expectations by tying in forecasts and requirements.

Our Technical Capabilities

There are many custom rotational molding companies in the market to choose from.

There is no other company that can match BDI in providing custom design and engineering solutions.

Our commitment is clear, from our dedicated Research & Development department to our engineering resources focused on:

  • Industrial Design
  • Project Engineering
  • Manufacturing Engineering
  • Quality Engineering
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What We Do For Our Customer Partners

Here is what we do for our customer-partners:

  • Product Design
  • Value engineering and value addition
  • Material selection based on functional requirements
  • Tooling Design
  • Tooling manufacturing
  • Product Trials
  • Product Assemblies
  • CNC or manual trimmings
  • Validation and Conformance to spec
  • Short lead time developments
  • Reliable just-in-time (JIT) deliveries with 100% consistency
  • Tooling storage, maintenance and upkeep
  • Inventory Planning
  • Inventory Management
  • Quality documents
  • Revision control
  • Type Approval Certification for regulation from ARAI, ICAT, etc.
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No matter what you need, our response is pretty much always the same:

Absolutely, we can do that!

Our Expertise

A fully staffed, 20+ member Engineering Department totaling over 125 years of engineering experience.
Our fully equipped Research and Development Team, also unique to the industry, has delivered critical products to the marketplace to meet environmental and other regulations.
We love talking to startups and anyone with an idea for a product. We’ve helped many of them go from dreamer to product manufacturer! From design, to development documentation to final specifications, even potential product partnerships. We can help with the entire process and help you with a go-to-market strategy!
Working with our engineering staff will give you the assurance that your projects are being optimized for efficient manufacturability while staying true to your original intent.

BDI will

  • Advise you on the suitability of your design for its intended purpose.
  • Assist you in creating appropriate specifications.
  • Verify critical specifications using a fully equipped testing lab.
  • Help identify, source and integrate components into your products, by drawing on an expansive knowledge base derived from the market segments we serve.
  • Our relationships with key vendors and our engineering capabilities allow us to assist you in selecting the appropriate component for your application.

Production Ready Designs

Our technical teams effectively integrate with our customer’s engineering and marketing groups to provide assistance with early product concept creation. Following the development of a selected concept, we support the creation of a production ready design.

This phase includes

  • Concept sketches in electronic format.
  • Feasibility models utilizing Advanced Surfacing and Style feature capabilities in SolidWorks.
  • Early expert evaluation of manufacturability and concept viability.
  • Product feasibility estimates.
  • Assistance with development of 3D models.
  • Firm production tool pricing and part pricing.
  • Full part production package including PFMEA, control charts, and capability plans

At BDI, we utilize our own comprehensive Production Part Approval Process (PPAP) based upon our intimate understanding of the process and developed in collaboration with our customers to ensure quality parts by design.

Production Part Approval Process

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Our robust 19-stage PPAP ensures our new developments are first time right, every time right. Our PPAP includes the following documents leading up to the Part Submission Warrant (PSW) with our customer.

  • Concept sketches in electronic format.
  • Feasibility models utilizing Advanced Surfacing and Style feature capabilities in SolidWorks.
  • Early expert evaluation of manufacturability and concept viability.
  • Product feasibility estimates.
  • Assistance with development of 3D models.
  • Firm production tool pricing and part pricing.
  • Full part production package including PFMEA, control charts, and capability plans

Highly evolved Enterprise Resource Planning (ERP) systems from SAP custom-built and best suited to roto-molding needs. Our systems effectively manage customer expectations by tying in forecasts and requirements.

Materials we work with

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  • Polyethylene
    • LLDPE
    • LMDPE
    • HDPE
    • XLPE
  • Polypropylene (PP)
  • Polyamide (Nylon)
  • Polybutene-1
  • Polycarbonates
  • PVC (Plastisol)
  • Flame Retardant materials
  • Anti-Static materials

Project Management

With state of the art ERP and other project management systems in place from SAP, BDI Group has a seamless way of handling developmental projects. Using its fully customized CRM best suited to the plastic moulding industry it is able to stick to its time line and is can reply to customers in time.

Weekly CFTs are held as a standard operating procedure for new projects under development.

Projects

  • Fully integrated Design Cell
  • High end CAD-CAM systems like SolidWorks, Catia etc.
  • Connectivity with customer using CAD-CAM, EDI
  • FEA simulations to support design and validation
  • Can truly manage projects from a ‘sketch off a napkin’ to commercialized products
  • Proprietary mould making standards – BDI manufactures moulds to exacting standards, the product of many years of experience. You can be confident that your moulds are built for the long run!

Case Studies

BDI has been spearheading innovation in the field of rotational moulding plastics in India.

Successful case studies include:

  • Conversion of mudguard made out of three individual injection moulded parts assembled together, into a single aesthetically beautiful rotomolded mudguard.
    Thereby enabling the automotive company to save on assembly line costs, converting three part nos. into one and doing all this by being price competitive.
  • BDI along with its valued customer have helped bring down the costs of fuel tanks in commercially sensitive projects by 20-25% even after cost settlements by suggesting alternate materials and newer technologies available in the ever changing markets. It is important that a vendor partner keeps themselves abreast with trends in the market and pass on benefits of advances to its customers. At BDI we do just that.

Testing & Conformance Capabilities

To consistently deliver the best parts each time it is important that we at BDI understand every facet of rotational moulding quality and keep it at the centre of every product development decision.

BDI quality team is supported by several quality apparatus from world renowned manufacturers at its plants, to name a few:

Material Level Testing

  • Computerised Twin-screw UTM Nx (for tensile, flexural, etc.)
  • Heat Deflection Temperature
  • Vicat Softening Point
  • SCR tester
  • IR Temperature gun
  • MFI tester
  • Humidity Chamber
  • IZOD Impact tester
  • Hardness tester shore A
  • Hardness tester shore D
  • Gel Content testing (for XLPE)
  • Carbon content testing
  • Hot air oven (Laboratory)

Product level testing:

  • TempLogger (PIAT)
  • Drop test
  • Pendulum Impact test
  • Overturn test
  • Hydraulic Test
  • Mechanical Strength test
  • Insert retention (pull-out)
  • Ultrasonic wall thickness tester (non-destructive)
  • Boro-scope camera (for internal surface inspection)
  • Filler cap pull-off test
  • Burst test*
  • Pressure drop testing
  • Weight test
  • Leakage testing
  • Static charge eliminator
  • Barcode tracking
  • Full dimensional inspection*

 

Barcode tracking of each and every tank sent by BDI enables us to better measure, control and improvise systems.

Tooling Development Services

FIRST TIME RIGHT AND EVERYTIME RIGHT is the motto BDI thrives on. To achieve this it is of paramount importance to ensure the rotational moulding tool is accurate to the minutest level and hence BDI ensures tools are developed in house and with the tightest control.

We are equipped to provide all standard textures required on the moulds as per part and customer requirement.
BDI specializes in making tools from the below materials:

  • Aluminium casting moulds
  • CNC machined aluminium moulds
  • Sheet metal moulds
  • Hybrid moulds

To achieve the right product from BDI tools the development team does a host of other activities such as:

  • Product designing & modelling
  • Tool designing & modelling
  • CAD / CAM
  • Tool manufacturing
  • Fixture designing & manufacturing
  • Development of inserts and child parts
  • Routine maintenance of tools and fixtures
  • Post processing line set up
  • CNC machining
  • FEA simulations to support design and validation
  • Stamping and embossing