Ethan Clarke
There are many companies that offer custom plastic parts, such as TAP Plastics, Marco Rubber & Plastics, Advanced Plastiform, Custom Plastics, Inc., and Xometry. These companies offer a range of services, including injection molding, thermoforming, and vacuum forming, to create custom plastic items for their clients. Injection molding is the most economical process for producing high volumes of plastic parts, while thermoforming is a cost-effective method for smaller production runs. Companies that provide custom plastic parts work with clients to select the appropriate materials and manufacturing processes to meet their specific needs.
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What You'll Learn
Injection moulding
The injection moulding process begins with the injection of molten material into a mould cavity. This material then cools and hardens, taking on the shape of the mould. The moulds themselves are usually made of metal, typically steel or aluminium, and are precision-machined to form the desired features of the part. Injection moulding can also be used to create parts with multiple materials, such as plastic parts with protruding metal screws. This process is known as insert moulding.
When designing parts for injection moulding, several factors must be considered, including warp, surface finish, stress, and resin additives. The choice of plastic material is also important, with popular options including acetal, nylon, ABS, PVC, polycarbonate, and polypropylene. Each material has unique characteristics and strengths that make it suitable for specific applications.
Several companies offer injection moulding services for custom plastic parts, including Marco Rubber & Plastics and Essentra Components. These companies work with customers to craft specialised solutions that meet their specific needs and standards. With their diverse production networks and expertise in the field, they can provide consistent quality and adhere to delivery schedules.
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Custom plastic panels
When it comes to custom plastic items, there are several companies that offer a diverse range of products and services. For custom plastic panels, here are some options to consider:
TAP Plastics
TAP Plastics is a plastic fabrication company that caters to DIY enthusiasts and home improvement projects. They offer a wide range of made-to-order materials, including custom plastic panels, polycarbonate and acrylic sheets, and plexiglass. TAP Plastics also provides laser engraving services, allowing customers to create informational signs, awards, machine labels, and more. Their polycarbonate sheets are known for their durability and resistance to breakage, impact, ultraviolet rays, heat, cold, and water damage.
BuyPlastic
BuyPlastic offers custom, cut-to-size plastic sheets in various materials such as plexiglass, polycarbonate, acetal copolymer, UHMW polyethylene, HDPE, and acrylic. They provide same-business-day shipping for orders placed by 3:00 p.m. (EST). BuyPlastic offers personalized assistance to help customers find the right products and provide guidance on cutting and drilling their plastic sheets.
Marco Rubber & Plastics
Marco Rubber & Plastics is an industry leader in custom sealing solutions, offering injection-molded custom plastic parts for engineered solutions. They have been providing reliable and long-lasting products since 1980, with a diverse range of materials and expertise in application-specific solutions. Marco Rubber & Plastics works closely with customers to craft specialized parts that meet their unique needs and standards.
EMachineShop
EMachineShop offers a range of custom plastic parts and provides insights into the properties of different plastics. They highlight the advantages of using plastic over metal in certain designs to reduce manufacturing costs. eMachineShop also discusses the benefits of different plastics, such as ABS, which is known for its strength, toughness, impact resistance, and heat resistance.
These companies offer a variety of options for custom plastic panels, catering to different needs and providing expert guidance in the process. Whether it's for a DIY project, a specific engineering solution, or cost-effective manufacturing, these sources can help you create the custom plastic items you require.
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Laser engraving services
Laser engraving is a process that uses a laser to engrave an object, resulting in a sharp and detailed finish. Laser engraving is an excellent option for custom plastic items as it can be used on a variety of plastic materials, including popular plastics like acrylic, nylon, ABS, PVC, polycarbonate, and polypropylene.
TAP Plastics, for example, offers laser engraving services for custom informational signs, award plaques, machine labels, and room numbers. They also offer a wide range of plastic materials, such as polycarbonate and acrylic, which can be cut to size and colour.
Laser Cutting Inc. is another company that provides laser cutting and engraving services. They can engrave on a wide range of materials, including plastics like acrylic (Plexiglass), wood, paper, fabric, metal, glass, ceramics, and more. During the COVID-19 pandemic, they specialised in laser-cut acrylic Plexiglass Shield Sneeze Guards, which they personalised with custom company logos.
If you are looking to start your own laser engraving business, JPPlus offers a wide array of engraving supplies, equipment, and accessories for both indoor and outdoor applications. They provide materials suitable for laser engraving, such as wood, engraving metal, and plastics, as well as ready-to-engrave blanks and engraving sheet materials.
For custom-made plastic parts, Marco Rubber & Plastics offers injection-molded plastic components for engineered solutions, produced with a broad range of materials to meet specific needs and standards.
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Thermoforming
Custom thermoforming is an ideal choice for a wide range of industries, including aviation, mass transportation, medical devices, and industrial equipment. Companies like Productive Plastics have decades of experience working with top thermoplastic material suppliers and can help you select the right material for your unique application.
Some common thermoplastic materials used in vacuum forming include Kydex, Boltaron, and Spartech, which meet strict requirements for strength, durability, impact resistance, and weather resistance. Vacuum thermoforming is also commonly used to replace fabricated sheet metal components and offers advantages over other manufacturing processes like FRP and RTM.
If you're looking for custom thermoforming services, T.O. Plastics and Plastic Ingenuity are two companies that specialize in this area. T.O. Plastics has been in the industry for over 75 years and provides high-quality thermoforming services for recreational, agricultural, and consumer packaging products. Plastic Ingenuity, on the other hand, is the largest custom thermoformer in North America and offers custom thermoformed packaging solutions for food, healthcare, and consumer goods industries.
When choosing a company for your custom plastic needs, it's important to consider their expertise, range of services, and ability to meet your specific requirements. Both T.O. Plastics and Plastic Ingenuity have established themselves as reliable providers of custom thermoforming solutions, catering to a diverse range of industries and applications.
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Selecting the right materials
Application and Functionality
First, it is crucial to have a clear understanding of the application and specific requirements of your product. Consider the unique functions your product needs to serve, such as permeability, friction, contact angle, transparency, moisture resistance, impact resistance, or wear resistance. For example, if your product needs to withstand high impact or harsh conditions, you might choose a thermoset plastic that can retain its shape and properties. On the other hand, if adaptability and reusability are priorities, thermoplastics like polyethylene, polycarbonate, and polypropylene offer more flexibility.
Production Method
The production method you choose will also influence your material selection. Common methods include injection molding, CNC milling, waterjet cutting, and 3D printing. Injection molding, for instance, is a cost-effective method for producing high volumes of plastic parts, but it may require additional processing afterward. Consider the advantages and limitations of each production method and how they align with your desired product outcomes.
Availability and Customization
Confirm the availability of your chosen material before finalizing your design. Some plastics are only available in certain regions or may be challenging to source. Additionally, consider the possibility of customization. If an off-the-shelf material doesn't meet your unique requirements, you can explore customizing additives to suit your specific needs.
Cost-Effectiveness
The cost implications of different materials can vary significantly. Most plastics are more affordable than metals by volume, and substituting plastic for metal can reduce manufacturing costs. Consider the balance between the performance characteristics you need and the associated costs. For example, ABS plastic offers high strength and toughness, while polypropylene provides excellent resistance to water, electricity, and acid at a lower cost.
Expert Guidance
Given the complexity of selecting the right materials, it is beneficial to seek expert guidance. Companies like Marco Rubber & Plastics, OMNI Technologies, and Protoshop offer extensive experience in custom plastic parts and can help you navigate the material selection process. They can ensure that your chosen materials align with your product requirements and manufacturing standards.
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Frequently asked questions
There are several companies that offer custom plastic parts, including:
- Marco Rubber & Plastics
- Advanced Plastiform, Inc.
- Custom Plastics, Inc.
- TAP Plastics
- Xometry
Some common plastics used for custom parts include:
- Polyethylene
- Polypropylene
- Acrylic
- ABS
- Polycarbonate
Custom plastic parts offer several benefits, including cost-effectiveness, flexibility in design and manufacturing, and the ability to meet unique specifications and requirements.
Common manufacturing processes for custom plastic parts include injection molding, thermoforming, vacuum forming, pressure forming, and twin sheet forming.
