Chloe Zhang
Manufacturing plastic parts can be a costly endeavour, especially when it comes to designing and fabricating moulds. However, there are ways to reduce costs, such as redesigning parts to be made from plastic sheets, which can be cut out cheaply and at large scale. 3D printing is also an option, but it is more suitable for low-volume production and prototyping. For those seeking a manufacturer, there are many companies that offer plastic injection moulding, such as Fast Plastic Parts in Colorado, USA, and Aline Components, a global manufacturer with over 50 years of experience.
| Characteristics | Values |
|---|---|
| Manufacturing techniques | Injection molding, 3D printing, CNC machining, laser cutting, subtractive manufacturing, SLA, SLS or MJF 3D printing, soft mold, water jetting, drilling |
| Manufacturing industries | Aerospace & defense, business services, construction, consumer goods & retail, energy & materials, high-tech, home & lifestyle, industrial equipment, life sciences & healthcare, marine & offshore, transportation & mobility |
| Materials | Acrylics, Polyesters, Silicones, Polyurethanes, Halogenated plastic, PA12, ABS, PLA, PET, Polyamide (PA), Polycarbonates (PC), Polyester (PES), Polyethylene (PE), thermoplastics, resins |
| Manufacturers | Fast Plastic Parts, Nicolet Plastics, Daystar, Aline Components, Dassault Systèmes, Xometry, Fictiv, Protolabs |
| Manufacturer locations | USA, Canada, UK, France, Netherlands, Germany |
| Manufacturer capabilities | Custom manufacturing, rapid prototyping, speedy manufacturing, quick order turnaround, full-service, quick response to issues, adaptable to changing demands, flexible to meet client needs, skilled personnel, quick turnaround times |
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What You'll Learn
3D printing for prototyping
3D printing is an excellent method for rapid prototyping, allowing manufacturers to improve product development. It is a quick and cost-effective way to create prototypes for testing and evaluation. With 3D printing, you can go from a computer-aided design (CAD) file to a physical prototype in a matter of hours or days, depending on the complexity of the design. This rapid turnaround time enables engineers and product development teams to iterate their designs much faster than traditional methods, such as clay modelling, which had far longer lead times.
One of the key advantages of 3D printing for prototyping is the ability to create functional prototypes with material properties similar to those of injection-moulded plastics. These prototypes can be used for comprehensive field and in-house testing, providing valuable feedback from customers and engineers. By testing the prototypes, manufacturers can validate their designs and ensure that the final product meets the desired requirements.
Additionally, 3D printing offers design flexibility and customization. Users can modify their designs and print multiple iterations to optimize the prototype before finalizing the product. This iterative process is integral to product design and engineering, ensuring that the final product is test-proven and market-ready.
While 3D printing is ideal for low-volume prototyping, it may not be cost-effective for producing hundreds or thousands of plastic parts. In such cases, traditional manufacturing methods like injection moulding or other rapid manufacturing techniques may be more suitable. However, 3D printing remains a powerful tool for rapid prototyping, especially when combined with in-house 3D printing capabilities, enabling manufacturers to bring their ideas to life quickly and efficiently.
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Injection moulding
The injection moulding process was first patented in 1846 by British inventor Charles Hancock, a relative of Thomas Hancock. However, the process was significantly improved in 1946 when American inventor James Watson Hendry built the first screw injection machine, allowing for greater control over the speed of injection and the quality of the final product. Hendry's machine also allowed for materials to be mixed before injection, enabling the addition of colour or recycled plastic.
In the 1970s, Hendry developed the first gas-assisted injection moulding process, which allowed for the production of complex, hollow articles that cooled quickly. This innovation improved design flexibility, strength, and finish, while reducing production time, cost, weight, and waste. By 1990, aluminium moulds were widely used in injection moulding, and the process had become a popular method for quickly manufacturing plastic parts.
Today, injection moulding is a widely used technique for manufacturing a variety of parts, from small components to large, complex shapes. The process is known for its ability to produce precise, consistent parts with a high level of detail and quality. Injection moulding machines can vary in size and capacity, with tonnage ranging from less than 5 tons to over 9,000 tons. The required tonnage depends on the projected area of the part being moulded, as this determines the amount of clamping force needed to keep the mould closed during injection.
When considering injection moulding for plastic parts, it is important to keep in mind that the process may be more cost-effective for larger quantities. For smaller batches, other methods such as 3D printing or soft moulding may be more suitable, as they can offer lower setup costs and faster turnaround times.
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![phrozen 3D Printer Rapid Resin [Aqua-Vanilla 8K], 405nm LCD UV-Curing Standard Photopolymer Resin for Highly Detailed Models, Low Odor Not Smelly Non-Brittle, Works Best with 8K 3D LCD Printer (1KG)](https://m.media-amazon.com/images/I/71sLpWrgeUL._AC_UY218_.jpg)
CNC machining
The cost of CNC machining depends on the complexity and size of the part, as well as the type of plastic used. The type of plastic will determine the machine required, the time it takes to produce the part, and the cost of the raw material. For example, ABS is a great general-purpose plastic for CNC machining due to its good machinability and dimensional stability, while POM is a good option for applications requiring low friction and high stiffness.
Companies like Protolabs and Emco Industrial Plastics offer CNC machining services for plastic parts. Protolabs guarantees consistent quality and fast turnaround times, while Emco Industrial Plastics specializes in high-performance plastics and state-of-the-art CNC machining services.
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Soft moulding
The process involves heating and using pressure to inject plastic material into a closed metal mould tool. A barrel is filled with resin pellets, which are melted, compressed, and injected into the mould. The mould cavity is then shot with hot resin and the part is moulded. Once the plastic cools, it hardens and takes the shape of the mould tool.
Soft tooling moulds can be made quickly and cheaply, but they wear out rapidly. However, their low price means multiple soft tooling moulds can be made at a lower cost than a single hard tooling mould. Soft tooling moulds also have lower temperature tolerances than hard tooling moulds.
For soft moulding, you can use companies such as Protolabs, Xometry, and Fictiv, which offer quotes for soft moulding services.
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Large-scale water jet cutting
Water jet cutting is an innovative technology that can be used for large-scale manufacturing of plastic parts. This technology is particularly useful for cutting plastic due to its precision, flexibility, and versatility.
Water jet cutting involves using an extremely high-pressure jet of water, or a mixture of water and an abrasive substance, to cut through a wide variety of materials. The water jet is accelerated to a high speed by special cutting nozzles and hits the plastic material to be cut. The high speed and high pressure of the water jet separate the plastic molecules, resulting in a clean and precise cut. The use of water jets eliminates the need for heat, which can be detrimental to the structural integrity of plastic. This process is gentle on the material and enables low-abrasion processing of plastics without heating them, thus preventing any structural changes even in temperature-sensitive materials.
Water jet cutting is capable of cutting complex shapes and intricate patterns with high precision. It can be used to cut plastic sheets, pipes, or foils without causing stresses, fusion, or cracking. The technology is also environmentally friendly as it does not produce harmful fumes, dust particles, or exhaust gases. The water used can often be recycled, and the garnet abrasive is a non-toxic material that can be recycled or disposed of in landfills.
Water jet cutting technology has been used for several decades to cut plastic and acrylic. KMT Waterjet, for example, offers waterjet cutting solutions with pumps ranging from 90,000 psi to 55,000 psi, which can significantly increase production rates and reduce costs.
Overall, large-scale water jet cutting is a highly effective method for quickly manufacturing plastic parts due to its precision, flexibility, and environmentally friendly nature.
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Frequently asked questions
Small plastic parts manufacturers are companies that produce plastic parts in small to moderate quantities. They are skilled at fulfilling particular customer demands, upholding quality standards, and guaranteeing economical production procedures. Some companies that offer these services include Daystar, Fast Plastic Parts, and Nicolet Plastics.
Some quick manufacturing methods for plastic parts include 3D printing, CNC machining, and injection moulding. 3D printing is a good option for prototypes and low-volume production, while injection moulding is a common method for producing plastic parts in larger quantities.
When choosing a plastic part manufacturer, it is important to consider the quantity of parts needed, the required materials and manufacturing process, and the manufacturer's expertise and capacity. It is also crucial to evaluate the manufacturer's ability to meet quality standards, delivery times, and customization requirements. Additionally, cost efficiency and sustainability practices may be important factors in the decision-making process.
