Skip to content 
At Munro & Associates, we’ve always emphasized the importance of not just the what of a product—but the how. That’s why our recent visit to DECKED’s manufacturing facilities in Defiance, Ohio, was more than just a tour. It was an inside look into the engineering, tooling, and craftsmanship that bring DECKED’s truck bed storage systems to life.
Founded over a decade ago, DECKED began with a simple yet powerful mission: help truck owners get more utility out of their vehicle beds. What started in a barn has grown into a highly sophisticated operation spanning over 320,000 square feet of dedicated manufacturing and assembly space.
Injection Molding at Scale
Our tour began in DECKED’s molding facility, where the backbone of their product—the injection-molded components—are made. With four large-tonnage injection molding machines on-site, this facility transforms reprocessed high-density polyethylene (HDPE) into the rugged components that make up their drawer systems.
Each machine is a marvel of engineering. Raw resin is fed into a hopper, melted through a screw mechanism, and injected into a custom-designed tool. The precision here is critical—not just to shape the part but to ensure durability, dimensional stability, and efficiency. And because DECKED’s components vary in size and application—from full-size truck drawers to mid-size Jeep Gladiator systems—tooling flexibility is key.
What’s remarkable is how DECKED’s engineering team designed tools that can adapt to various truck models with just a few insert changes. A single set of tools can accommodate both Ford F-150s and GMC Sierras, and even different bed lengths. This modular approach maximizes output while reducing tooling redundancy and storage overhead.
Robots, Tonnage, and the Dance of Precision
DECKED’s largest machines—the 2700-ton and 3200-ton presses—are dedicated to manufacturing the biggest parts of the drawer system. These machines operate alongside six-axis robots that choreograph a precise ballet: inserting steel tubes for added structural support, retrieving finished parts, and resetting the mold for the next cycle. Each deck panel takes about 120 seconds to complete, a testament to both the size of the parts and the complexity of the cooling and forming process.
These robots don’t just improve efficiency—they also ensure consistency, even accounting for environmental changes. For example, DECKED recalibrates robot movements quarterly to account for temperature shifts in the factory, which can impact the placement of steel inserts by mere fractions of a millimeter.
Resin, Reinforcement, and Real-World Considerations
DECKED’s drawer systems are built to last, and their choice of materials reflects that. The HDPE used in production includes a UV stabilizer, black colorant, and a foaming agent. These additions ensure that the parts won’t degrade under the sun. They also ensure that they maintain a consistent appearance, and fill molds completely without the need for excessive tonnage. The foaming agent, in particular, allows DECKED to use smaller machines for larger parts, cutting down on energy use and floor space.
Switching colors, however, is no trivial task. Changing from black to tan or any other hue requires purging 250 to 400 pounds of resin—enough to make dozens of parts. As a result, DECKED smartly batches production to minimize downtime and reduce material waste.
From Parts to Product: The Assembly Process
Once molded, parts travel across the lot to DECKED’s South Building, where they undergo final assembly. The facility, which has grown from 50,000 to over 250,000 square feet, houses warehousing, packaging, and multiple assembly lines.
Each drawer system begins with deck panels that are router-cut to fit specific truck bed dimensions. These panels don’t “know” which vehicle they’re destined for until this stage—another example of DECKED’s adaptive manufacturing approach.
The assembly process is streamlined and worker-focused. Structural supports, drawers, tie-down brackets, and steel C-channels come together efficiently. This creates a strong and secure system capable of holding 2,000 pounds. Components are pre-assembled as much as possible, sparing customers from complex setups and ensuring every unit arrives ready for action.
Meeting Customers Where They Work and Play
Who buys a DECKED system? While many truck owners never scratch the surface of their vehicle’s potential, DECKED serves a different kind of customer—contractors, ranchers, adventurers, and weekend warriors who put their trucks through real work.
From job sites to backcountry trails, DECKED’s customers rely on their drawer systems for security, organization, and ease of access. Whether they’re storing tools, gear, or emergency supplies, DECKED provides a level of functionality that makes the truck bed more than just an open box—it becomes an essential workspace.
That versatility has shaped the product itself. DECKED balances ruggedness with flexibility. Customers can add cargo glides, secure accessories, or opt for cases in different colors. And when they do, DECKED’s team ensures that the system will fit—not just physically, but functionally—into their daily lives.
Engineering with the Future in Mind
As a manufacturer, DECKED doesn’t just build a product—they build a process. They’ve designed their tooling, floor plan, and supply chain to scale with demand while staying nimble enough to serve a wide customer base.
What sets them apart is not only the quality of the product. But it’s the depth of engineering thought that goes into every phase—from CAD design to tool construction, from robot programming to assembly line layout. Every decision is rooted in practical problem-solving and years of manufacturing experience.
For us at Munro, this tour reinforced something we already believe: great design is only as good as the process behind it. DECKED’s approach shows what’s possible when you bring engineering, manufacturing, and user experience into perfect alignment.
So next time you see a truck with a DECKED system in the bed, remember—it’s not just what you see that matters. It’s how it was made.
Keep an eye out for more in-depth insights from the Munro Live team.