Plastics are polymers made of elements like hydrogen, chlorine, nitrogen, and oxygen. The original thought behind manufacturing plastic parts was to imitate materials like metals to get similar product quality with lighter weight.
Manufacturing plastic parts that are customized for a particular use is a step by step process. There is a set sequence of events that need to be followed during the manufacturing process.
Additionally, when it comes to custom plastic parts, it is also important to consider the practical requirements along with the geometric complexity of the design.
Making parts through plastic injection molding is the latest trend in the world of plastics. The ability and ease of using different resins and combinations through the injection mold technique has multiple advantages.
The article walks you through some of the key challenges and steps involved in the process of manufacturing plastic parts.
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Ideas create products
Creating custom plastic parts is not usually as complicated as it is perceived to be. Especially, with the invention of plastic injection molding techniques, everyone who has an idea can see it turn into a custom-designed plastic part.
The first step is to have a great idea and a clear plan of action. So what are the steps to ensure that the product idea in your head turns out to be just the same when manufactured?
Start with making a clear sketch ensuring that all the important parts are drawn in detail. Hiring professional plastic part designers for making the sketches is also a good idea. Pointing and labeling each part and trying to get them geometrically accurate is important.
manufacturing plastic parts
Once a draft sketch is drawn, an engineer from the manufacturer’s team can create a 3D model of the plastic pat. Needless to say, this stage may involve multiple trials and errors to create a part that’s structurally feasible and functional.
Working with a good team and choosing a leading manufacturing partner is important.
Plastic injection molding is the preferred technique adapted by most leading manufacturers for creating custom plastic parts. The process is more consistent in wall thickness and close tolerances and offers a perfect balance of functionality and costs.
Additionally, plastic injection molding advantages include the maximum flexibility to create products that are complex in their design.
Once your idea is presented clearly in a 3D version with all geometric details, the next steps involve creating plastic prototypes and choosing the right kind of plastic resin for the injection molding process.
A choice in the mold design and tooling approaches (soft tooling, single cavity pull ahead tooling) to be applied may also be made.
Finally, it is also at this stage that you discuss your budget with the manufacturing team. Budget plays a crucial role in the choice of different plastic resins. You would need to create a path that balances your budget along with the quality of the product that you desire.
Once the budget is agreed and the materials are chosen, the actual manufacturing process starts. The entire manufacturing process can actually be summed up as building the mold and injecting the resin in the mold to create the desired parts.
An idea gets transformed into an actual product. The following section presents in detail the key steps involved in the manufacturing process.
Key steps involved of the plastic Parts
Below mentioned are the basic steps involved in manufacturing custom designed plastic parts.
1. Draft a design
As mentioned earlier, the first step is to come up with a design for the plastic parts that are required to be created. The process starts by sketching the design on a piece of paper. It is important to add all the geometric details.
The design is then converted to a 3D model. At this stage, there is often a need to make multiple changes in the design of the part to make it achievable and yet functional.
manufacturing plastic parts
2. Choose the plastic resin
Once a 3D model is created, it is time to discuss and choose the type of resin that is most suitable for manufacturing the part. All plastic resins have different properties in terms of hardness, flexibility, and durability. Additionally, plastic resins also vary in their costs.
It is hence important to balance the costs and the functionality of the plastic part that is desired to be created.
3. Decide on the type of plastic molding process
Various molding methods are used by plastic part manufacturers across the globe. However, plastic injection molding is considered to be the most superior as well as popular technique.
The choice of process is usually dependent on the design, the applicability of the products, the quantity of plastic parts needed and the time available for manufacturing.
Plastic injection molding balances all the aforementioned criteria to give the users plastic parts that are functional, durable, and cost-effective.
4. Build a prototype
Developing a prototype may not always be necessary but is a highly recommended step. Creating a prototype that resembles the final product helps you see the flaws of the design before the plastic parts are manufactured in bulk.
It is not always possible to see the issues on a 3D model until the same comes live. Checking the prototype helps fix the issues that may otherwise not be apparent.
Various prototype tools like resin prototype machines are available with the plastic part manufacturers.
5. Create the designed part
The design is presented, the 3D model created, budget discussed, plastic resin selected and the prototypes have been approved. Finally, it is time to send the product for manufacturing.
Choosing a reputed manufacturer will go a long way in ensuring that your custom plastic parts come out as desired.
Most manufacturing companies are equipped to handle all of the above stages for the customers.
Tips to improve the efficiency of the manufacturing plastic parts
Even after theoretically ensuring that each of the aforementioned steps is worked out well, problems can arise during the process. In the end, it is all about execution. Executing a project well minimizes the hassles.
Following are some handy tips to ensure that your plastic part manufacturing process has a smooth journey:
Choose your design and manufacturing team carefully- Ensure that the team of professionals that you choose have adequate expertise. It is important that the professionals help you see the loopholes in your design before you spend an entire budget on bulk manufacturing.
Be open to challenges and take risks. After all, this is your own unique idea.
While you should definitely show up your stronger front by being open to risks, it is equally important to be practical in your approach. Be flexible with your team and show openness to incorporate the suggested changes.
Choose quality over costs. While budget constraints must always be kept in mind while choosing a material, ultimately, it is the quality of your plastic parts that will grab you a place in the market. Ensure that you do not compromise on the quality while cutting down your costs.
Stay in the loop and maintain regular touch with your manufacturing team during the entire process.
With the advent of technology, the world of plastic part manufacturing has seen some major changes. The manufacturing processes used these days are much less complex.
Additionally, the use of modern technologies like injection molding has reduced the chances of inaccuracies in the plastic parts being manufactured. The availability of a wide range of plastic resins and the inventions in mold design engineering have increased the applicability options.
Further, the utilization of robotics has minimized the need for labor and has made the manufacturing process highly cost-efficient.
As long as a reliable and reputed team is chosen for the job, manufacturing plastic parts can be done with high accuracy and precision.
What Is Plastic Parts?
The term “plastic fabrication” describes the process of creating, producing, and/or assembling custom-designed plastic products or high volume parts out of plastic or composite materials. Plastic fabrication includes a variety of processes, such as:
1. Plastic extrusion
2. Plastic pultrusion
3. Plastic welding
4. Thermoforming
5. Injection molding
6. Rotational molding
7. Blow molding
8. Plastic CNC machining
9. Vacuum casting
10. Stereolithography
11. Fused deposition modeling
12. Selective laser sintering
These methods each has a different set of processes. Plastic’s adaptability, cost-effectiveness, and light weight make it versatile, and for that reason, it is widely used.
What Is Plastic Fabrication Also Known As?
“Plastic processing” and “plastic manufacturing” are other terms for plastic fabrication. This phrase can refer to any or all of the steps that go into shaping and molding plastic materials into finished goods.
What Is the Purpose of Plastic Fabrication in Manufacturing?
Plastic fabrication is used in manufacturing to create finished goods with specific forms and functions from raw plastic materials. Due to plastic’s flexible nature and affordability, this process enables the production of a variety of items used in a variety of industries, including consumer goods, automotive components, medical devices, and electronics.
What Are the Industries That Use Plastic Fabrication?
The automotive, food, aerospace, electronics, medical, packaging, and consumer goods industries make use of one or more plastic fabrication methods to create finished products. The adaptability of plastic fabrication enables it to serve a variety of applications in these industries. Injection molding is a widely used plastic fabrication method in various industries. The process starts with molten plastic material injected into a mold cavity, where it cools and solidifies to form the desired shape. Additionally, the medical field employs injection molding to create items like syringes, IV components, and sterile medical equipment.
How Does Plastic Fabrication Work?
Plastic fabrication involves multiple processes, starting with design and planning, material selection, material preparation, forming and shaping, finishing and assembly, and concluding with quality control and inspection. There are several plastic fabrication methods, each with various processes. Listed and discussed below are three common methods:
3D Printing: By constructing objects layer by layer from a computer model, 3D printing emerges as a highly adept method for crafting intricate designs and prototypes. This process involves creating a 3D model using software, selecting a compatible plastic filament—important when utilizing an FDM printer—preparing and loading the filament into the printer, and then sequentially extruding the model onto a build platform. The printed object undergoes polishing during finishing and assembly, followed by a final inspection to ensure accuracy and identify flaws.
Extrusion: Extrusion is a popular method for shaping plastic pellets into continuous objects like sheets and pipelines. Fundamental procedures include designing the required die form, choosing appropriate plastic pellets depending on their qualities, melting the pellets, and then running the molten plastic through the die to shape it. The operation is finished by cutting the continuous shape to the necessary lengths and checking for uniformity and flaws.
Plastic Injection Molding: The plastic injection molding process creates complicated pieces by pouring molten plastic into a mold. Plastic pellets are heated and injected into the mold after choosing the right material and designing the mold. There, they cool and solidify inside the mold’s shape. After this, the object is taken out of the mold and thoroughly inspected for flaws, dimensions, and general quality.
What Is the Step-by-Step Process of Plastic Parts?
Each step of the plastic manufacturing process, from design to delivery, is essential for economically transforming raw polymeric materials into usable products.
1. Design and Planning
The first step in manufacturing a successful product is to understand the product requirements, including (but not limited to) size, dimensional tolerances, mechanical properties, and chemical and temperature resistance. A preliminary design, usually a 3D computer model, can then be created.
2. Material Selection
The first step in manufacturing a successful product is to understand the product requirements, including (but not limited to) size, dimensional tolerances, mechanical properties, and chemical and temperature resistance. A preliminary design, usually a 3D computer model, can then be created.
3. Material Preparation
Prepare the selected materials by extruding, molding, or cutting them into usable shapes.
4. Forming and Shaping
Shape the plastic materials into the desired product using methods like injection molding, thermoforming, or CNC machining.
5. Finishing and Assembly
Assemble subcomponents into final parts if necessary and add any necessary features. Other finishing processes that may be needed include: burr or flash removal, surface smoothing, painting, sealing, or curing.
6. Quality Control and Inspection
Verify that the part meets all customer specifications by using statistical process control and inspection.
7. Packaging and Delivery
Deliver the finished products to the intended recipients in packaging that adequately protects the product from damage during transport.
Skipping any of the steps listed above may result in the production of plastic parts that are defective or incomplete. Each step is crucial to achieving success and meeting customer expectations.
XTJ is a leading OEM Plastic Parts Manufacturer that is dedicated to providing one-stop manufacturing solutions  from prototype to production. We are proud to be an ISO 9001 certified system quality management company and we are determined to create value in every customer relationship. We do that through collaboration, innovation, process improvements, and exceptional workmanship.
