Optimizing Your Plastic Parts for Fabrication

You've got a fantastic idea for a new product, maybe even a solution to a nagging problem, and you know plastic is the material that will bring it to life. But how do you actually make something out of plastic?

Perhaps you're feeling a bit overwhelmed by the sheer number of options, or maybe you're worried about making a costly mistake. You're not alone! Many innovators face these exact questions when they're starting out.

A strong partnership with a custom plastic fabrication company is key to transforming your innovative designs into high-quality, cost-effective plastic components.

To truly unlock the benefits of plastic manufacturing, it's crucial to design with the process in mind.

This article offers key insights from our experience, guiding you through the critical design considerations that lead to successful and efficient plastic part production.

1. Wall Thickness

Wall thickness is fundamental to both the structural integrity of your part and the efficiency of the manufacturing process.

Consistency is Key: Aim for uniform wall thicknesses throughout your part. Inconsistent thicknesses can lead to warping, sink marks, and internal stresses as the plastic cools. If variations are necessary, ensure smooth, gradual transitions to minimize these risks.
Avoiding Excess Material: While it might seem counterintuitive, overly thick sections can cause problems. They cool slowly, increasing cycle times and the likelihood of cosmetic defects.
Finding the "Sweet Spot": Every material and process has an optimal minimum wall thickness. This will be guided by your chosen material and the fabrication method (e.g., injection molding, vacuum forming). A wall that's too thin can lead to incomplete fills or a fragile part.

2. Bend Radius

Corners and bends in your design might seem minor, but they play a significant role in your part's durability and how easily it can be manufactured.

Say No to Sharp Corners: Sharp internal and external corners create stress points where cracks are more likely to form. They can also hinder material flow during molding.
Draft Angles for Easy Ejection: For molded parts, draft angles are essential. These slight tapers on vertical walls allow the part to be easily ejected from the mold, preventing damage to both the part and the tooling. Incorporate appropriate draft into your designs.

3. Tolerances

Plastic parts behave differently than metal, especially when it comes to dimensional stability. Tolerances mean the acceptable range of variation in the dimensions, properties, or performance characteristics of a manufactured part. To try to avoid incurring unnecessary costs, consider:

Understand Material Shrinkage: All plastics shrink as they cool. The amount varies by material, and this is accounted for in tooling. Discuss your material choice and its specific shrinkage rate to ensure accurate dimensions.
Process Capabilities: The manufacturing process chosen impacts the achievable tolerances. Injection molding, for example, typically offers tighter tolerances than vacuum forming.
Strategic Tolerancing: Identify which dimensions are truly critical for your part's function and assembly. Applying tight tolerances only where absolutely necessary helps control tooling costs and manufacturing time.

4. Material Behavior

The plastic material you choose is the backbone of your part's performance and dictates many design considerations. Select the best material for your application.

Matching Material to Application: Consider your part's intended use to understand the necessary mechanical properties (strength, impact resistance) and thermal properties (heat resistance).
Environmental Factors: Will your part be exposed to chemicals, UV light, or moisture? Ensure the chosen plastic has the appropriate chemical resistance and stability for its environment.
Processability and Cost: Also consider how easily a material can be processed and its cost-effectiveness, balancing performance with your budget.

Partnering for Success

Our goal is to turn your innovative ideas into high-quality, functional plastic parts. By partnering with us forcustom plastic fabrication and considering these design principles, you can ensure a smooth, efficient, and cost-effective fabrication process, delivering parts that meet your exact specifications and stand up to real-world demands.

Ready to discuss your next project? American-made since 1945, if you can dream it, we can make it. Collaborate with us by giving us a call at (800) 783-3674 or fill out our contact form today!