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injection molding
Disc golf discs are made using injection molding. Raw plastic pellets are dried, melted, and injected into molds, then cooled and ejected. MVP's signature overmold process involves two separate injection molding steps for the core and the outer rim.
- 🔴 The core of the disc is molded first, followed by the overmold, which is a different material, often with a different color or density.
- ⚙️ Robots are extensively used for material handling, part transfer, and assembly, increasing efficiency and precision.
- 💨 The process involves precise control of plastic temperature, pressure, and cooling time to achieve desired disc properties like stability and grip.
- 🖨️ After molding, discs are trimmed, have weight marked by laser, and then receive graphics via a heat-transfer foil process.
- ♻️ Waste plastic from the process is reground and used to create a recycled disc line called R2.
A close-up of a disc golf disc's edge with a red arrow pointing to the overmold, next to a smiling man holding a disc.