MRPC Expands Cleanroom Capacity at Butler, WI Headquarters to Support Growth and Advanced Silicone Molding Automation

MRPC, a leading medical device contract manufacturer, has completed an 11-month cleanroom expansion and automation project at its headquarters campus in Butler, Wisconsin. The multi-million-dollar capital investment enhances MRPC’s ability to scale with customer demand while advancing automation and innovation in liquid silicone rubber (LSR) and high consistency rubber (HCR) molding for the medical device industry.

MRPC’s Butler campus now features seven cleanrooms supporting a blend of thermoplastic and silicone injection molding, transfer molding, extrusion, secondary operations and assembly. As part of this latest initiative, MRPC redeveloped a portion of one of their ISO 8 cleanrooms to create several high-capacity, fully automated silicone molding cells designed for precision and efficiency in medical applications.

The redeveloped space houses five new, self-contained automation work centers. Each molding machine—ranging from 130 to 150 tons—is factory designed for high-precision processing of LSR and HCR materials. Integrated cartesian-style, servo-driven robotics handle part removal and downstream operations, working in tandem with multi-cavity, cold deck, flashless molds and custom end-of-arm tooling to demold parts directly from the molding cycle.

By consolidating operations into a contained, automated environment, MRPC has established continuous product flow while minimizing overhandling and enhancing part cleanliness—an essential advantage for customers in highly regulated and quality-sensitive industries. The cell is managed by a self-directed team using MRPC’s Manufacturing Execution System (MES), providing real-time production visibility through a streamlined, paperless workflow.

“Automation ensures a stable and repeatable molding cycle,” said Brunson Parish, Director of Technology Development at MRPC. “Robotics perform repetitive tasks with greater speed and precision, while integrated process monitoring systems continuously verify and control molding parameters and part integrity. If validated process limits are exceeded, the system automatically segregates product, protecting quality and maintaining consistency shot after shot.”

A key focus of the expansion is flashless silicone molding, a technically demanding approach that eliminates the need for secondary trimming operations. Flashless molding produces higher-quality parts, reduces contamination risk, minimizes waste, and lowers overall product costs. By eliminating post-process material removal, MRPC reduces the potential for part damage while delivering cleaner, more efficient manufacturing outcomes for critical medical components.

The project required upgrading utility infrastructure to support the new equipment, and installing advanced machine and mold handling systems. Throughout the redevelopment, MRPC maintained its commitment to operational excellence and customer continuity.

This investment further strengthens MRPC’s customer partnerships by delivering state-of-the-art molding methodologies designed to improve efficiency, cost-effectiveness, and scalability. It also reinforces the company’s long-term strategy of integrating advanced automation with deep technical expertise in silicone, rubber, thermoplastics, extrusion, and multi-material molding to support complex medical device programs.

In collaboration with world-class tooling and automation suppliers, MRPC executed a multi-tool turnkey development package encompassing mold design and build, process development, automation integration, and machine optimization. The partnership reflects MRPC’s commitment to aligning with industry-leading suppliers to drive continued technical growth.

“While investment in cutting-edge equipment remains central to our competitive strategy, we recognize that technology alone is not enough,” said Parish. “Our continued focus on recruiting top talent, providing advanced technical training, and strengthening the skills of our team ensures we are well positioned to support increasingly complex customer programs and future growth.”

With this cleanroom expansion, MRPC continues to scale responsibly—meeting customer needs with innovation-driven solutions in silicone and plastic molding while reinforcing its position as a trusted technical partner in advanced medical device contract manufacturing.