Injection molding has given way to the production of a variety of plastic components, including seals, gaskets, fasteners, covers, etc. For such plastic products to be successful in an application, it is important that any defects or errors be eliminated before the production phase. This can be achieved during the prototyping phase.
Prototype parts can be used to ensure that the final product will meet the application equipment’s requirement. Prototyping of various plastic products can benefit applications in communications, product research, and engineering.
The Importance of Plastic Parts Prototyping :
There are a few important reasons why prototyping should be made a mandatory part of the plastic component design process:
- Prototypes can be used to properly define the size, shape, appearance, and function of a part or product. Creating a prototype can lead to higher interaction between design and manufacturing teams, thus enabling the production of an efficient and durable product.
- Prototyping includes simulations. The simulation packages help reduce the need for major tool modifications in the production phase.
- This process allows for various changes to be made to the product in the design phase itself. It results in the minimization of costs in the overall production cycle.
- Prototype creation can be achieved using a variety of techniques. General techniques include sawing, milling, drilling, turning, or grinding. Prototypes can also be created using casting, lamination, and machining process.
- Prototypes also undergo rigorous testing. As the prototype is essentially a model, there is a possibility that it may not withstand the testing procedures. For this reason, manufacturers enhance the strength of the product for testing. This can be achieved with assembly or bonding techniques. Manufacturers can also enhance the prototype with plastic, wood, or metal parts.
- Machined plastic prototypes can be produced to high degrees of accuracy. Generally, manufacturers can achieve at least ±0.025 mm accuracy with machining equipment.
- Prototypes can be produced with a variety of materials to suit the main application. Depending on the application, manufacturers offer material choices ranging from ABS, PVC, and acetals, to nylons, polycarbonate, and fluoropolymers, and others.
- Prototypes are designed using CAD techniques, and are produced using CNC machining equipment. The use of these solutions result in the reduction of costs in terms of labor, complex designs, and expensive production runs.
The above points elucidate the importance of prototyping in the plastic parts design process. Effective prototyping can lead to the production of precision engineered and durable plastic components.
