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The Key Steps to Customize Size and Design of Plastic Injection Parts

Customizing the size and design of plastic injection parts requires a systematic approach to ensure functionality, manufacturability, and cost-efficiency. Below are the key steps involved in the process:

 

1. Define Requirements: Identify the part’s purpose, load conditions, and environmental exposure (e.g., temperature, chemicals).

Determine dimensional tolerances, material properties (strength, flexibility), and regulatory standards.

 

2. Conceptual Design: Create sketches or 3D models using CAD software (e.g., SolidWorks, AutoCAD).

 

3. Material Selection: Choose thermoplastics (e.g., ABS, polypropylene) based on durability, cost, and molding behavior. Additives (e.g., glass fibers, UV stabilizers) may be incorporated for enhanced performance.

 

4. Design for Manufacturability (DFM): Optimize wall thickness (typically 1–4 mm) to prevent defects like sink marks or warping. Incorporate draft angles (1–3°) for easy ejection from the mold. Avoid sharp corners; use radii to reduce stress concentrations.

 

5. Mold Design & Fabrication: Split the mold into core and cavity halves, accounting for parting lines and ejection pins. Select mold steel (e.g., P20, hardened steel) based on production volume. Integrate cooling channels to reduce cycle time.


6. Production & Testing: Conduct trial runs to identify flow issues (short shots, flash) and adjust parameters (pressure, temperature). Perform quality checks (dimensional accuracy, stress tests) on final parts. 


7. Post-Processing (if needed) : Apply secondary operations like painting, ultrasonic welding, or CNC machining for precision features.

 

By following these steps, manufacturers can achieve high-quality, customized plastic parts tailored to specific applications while minimizing costs and lead time.


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