Before starting a new design, it’s important to research similar products within the company or the industry. This step focuses on:
By referencing successful designs and avoiding problematic structures, the overall development process becomes more efficient and reliable.
Based on the product's appearance design and functional requirements, the following considerations are made:
This phase ensures the product achieves its visual appeal while maintaining functional integrity.
Strength analysis is critical to ensure the durability and performance of plastic parts:
The combination of wall thickness, ribs, and effective connections ensures parts meet both individual and overall structural strength requirements.
Draft angles ensure smooth ejection of parts from the mold without damage. Consider the following factors:
Draft angles are carefully optimized to balance aesthetics, material properties, and manufacturability.
| No. | Component Category | Recommended Material | Label Example | Notes |
|---|---|---|---|---|
| 1 | Handle Category | Flame Retardant ABS | Flame Retardant ABS | When adding color, ensure granule extraction. Vacuum plating and electroplating performance are poor. |
| 2 | Small Panel Category | Flame Retardant ABS | HF-606 | When adding color, ensure granule extraction. Vacuum plating and electroplating performance are poor. |
| 3 | Guide Rail Category | PA66 + Glass Fiber | PA66-RG25 | The parts may appear rough, color matching is difficult, and this material has poor toughness. Small structures like hooks are prone to breaking. Structural designs should include rounded edges to enhance strength. |
| 4 | Lamp Cover, Light Guide Pillar | PMMA, PC | PMMA 560F | Transparent PC has good machinability, does not crack easily, but is expensive with slightly poorer transparency. PMMA is brittle but has better transparency and lower cost. The poor flowability of PC and PMMA must be considered in design. |
| 5 | Lens, Transparent Window | Transparent PC | Dow 302-05 | The flowability of PC and PMMA is poor, so this must be fully considered in the design. |
| 6 | Dustproof Net | Woven Dustproof Net | PPK15 X13H/B Zhuhai Jin Hai Sanxi Company | For use in environments with excessively high temperatures, material replacement should be considered. |
| Flame Retardant ABS | Flame Retardant ABS | |||
| 7 | Dual-Color Plastic Nameplate | Anti-Electroplating, Weather-Resistant Material | PC | Dual-material injection molding is relatively complex. |
| Electroplating Material | ABS PA-757 |
| No. | Category | Process Description | Surface Effect | Notes |
|---|---|---|---|---|
| 1 | Original Plastic Glossy Surface | Mold cavity polished to achieve glossy finish | The plastic surface is smooth and glossy. | The higher the precision of the mold surface size, the better the gloss effect and the smaller the light reflection of the parts. |
| 2 | Original Plastic Textured Surface | Textured pattern added on top of mold polishing | The plastic surface shows fine textures with varying surface gloss effects. | Textures can be divided into glossy textures, semi-gloss textures, and matte textures. Coarse textures generally do not combine with spraying. The coarser the texture, the poorer the scratch resistance. Matte textures are prone to scratches. |
| 3 | Plastic Surface Spraying | Paint is sprayed on the plastic surface | Achieves different colors, gloss levels, tactile sensations, and varying wear resistance. | Spraying enhances the gloss and matte effect and visibly improves the appearance of plastic parts. However, it significantly increases costs. |
| 4 | Plastic Surface Silk Printing, Transfer Printing | Local surface printing on plastic parts | Allows for printing of text and patterns with different color effects. | The effect mainly depends on the color of the ink. |
| 5 | Plastic Surface Vacuum Plating | Vacuum plating process | Achieves different colors and gloss effects. Can produce semi-transparent lamp covers or panels. | Gloss depends on the original plastic state; color comes from the vacuum plating material. Vacuum-plated products are brittle and often require a protective coating to improve wear resistance. |
| 6 | Plastic Surface Electroplating | Plastic electroplating | Achieves different colors and gloss effects but cannot produce semi-transparency. | Gloss depends on the original plastic state; color comes from the electroplating material. Electroplated products typically have good wear resistance, but some plastic materials cannot be electroplated. |
| 7 | Plastic Surface IMD | A process where a thin printed film covers the plastic surface. | The film is wear-resistant and achieves printed effects; this method is widely applicable to plastic surfaces. | The film typically covers the surface. It can cover white film, silk printing, or UV lacquer after printing. This method has requirements for sharp corners and concave-convex designs. |
| 8 | Plastic Surface IML | A thicker film layer, which can be considered as a standalone component applied on the plastic surface or inside. | The film is wear-resistant, and its thickness can achieve a multi-layered 3D effect. | The film is generally applied to the surface. This method has requirements for sharp corners and concave-convex designs. |
A systematic approach to plastic part design ensures that products meet functional, aesthetic, and manufacturing requirements. By benchmarking existing designs, determining part segmentation, analyzing strength, and optimizing draft angles, manufacturers can produce high-quality, reliable parts.
At JBR, we are Plastic Fabrication Specialists and a One-Stop Injection Plastic Parts Provider. We offer tailored solutions for designing and manufacturing bespoke plastic parts that meet the highest standards of quality and precision.
1. Why is benchmarking existing designs important in plastic part design?
Benchmarking helps identify proven solutions and avoid repeating previous structural issues.
2. How do you ensure part strength in plastic components?
Strength is ensured by optimizing wall thickness, adding ribs or gussets, and enhancing connection points.
3. Why are draft angles important in injection molding?
Draft angles prevent surface damage and enable smooth ejection from the mold.
4. What materials are suitable for different product types?
Materials like PP, ABS, PA, and PEEK are recommended based on the product’s functionality and durability needs.
5. How can JBR help in plastic part design and manufacturing?
JBR provides end-to-end solutions, including design optimization, material recommendations, and precision manufacturing for custom plastic parts.
