Manufacture of plastic products in small and medium series

There are technological products whose market size is limited to small quantities. These products are usually characterized by a high level of complexity as they provide a precise response to a very specific need. Examples of these products can be found in the fields of military equipment and medical equipment.

The importance of product design

Even if you have an idea for an effective and necessary product, and even a working prototype, you should invest a great deal of thought into designing and making it attractive to the particular market segment. In fact, many times the inventor is unfamiliar with the range of options for manufacturing plastic products, which is manifested, for example, in an existing model that does not look good and is not comfortable enough to use, so its chances of success are low. This is precisely where the importance of professional assistance from a product designer specializing in the design of plastic products, which is capable of optimizing the structure and manner of use, maximizes the raw material properties, while minimizing time and costs. To do this, research the features and functions intended for the product, understand the storage, logistics and transport aspects, and, on the other hand, be familiar with the particular market (such as competing products) and the target audience. Also, at this stage, planning aspects will already be taken into account when the design is tailored to them to shorten the following processes.

Moving to the planning stage

We agree on the agreed design in the next step for the plastic injection technology, including the location of the distribution line and the adjustment of the angle of extraction. At the same time, technological solutions are provided for unresolved aspects in the design phase and optimized undercarriage reduction, reinforcement where necessary, and creating as uniform wall thickness as possible. At this point, it is recommended to perform a product flow analysis to check for optimal injection points, fillings, expected distortions and the like, and accordingly update the product design to obtain the best result production.

In case the product is required to meet defined forces, strength analysis (Finite Elements Analysis (FEA)) can be performed and verified that the product meets them.

Building a prototype

After completing the previous steps, you can move to building a prototype, which aims to allow tangible contact with the product and, as needed, to make adjustments, modifications, repairs and improvements before moving on to the manufacturing stage.

To do this, you can use a number of technologies such as chip processing or 3D printing, but the best way to illustrate the product is by building a true single-enclosed template (experimental template).

Template design and production

Now we are actually entering the manufacturing process which begins with the design of the template and the DFM document, which contains the principles for design and production and the template (the type of raw material, distribution line location, the nature of the product area, and more). Only after the client’s approval of the DFM can you enter the work, and naturally, it is of great importance for a thorough examination of the document by the client.

The production itself

The last stage can be divided into two. The first part is a first plastic production series in which it is recommended to produce relatively small quantities of products, so that if repairs are found to be necessary they will not incur too high costs.

Now that the first series is satisfactory, it is possible to switch to regular production and return, ensuring full accuracy between the final products and the original. Precision is obtained by meticulous documentation of the process from the very first production, including injection machine parameters, raw materials, approved samples, quality specifications, and more.

Clean Pack specializes in the production of high quality small and responsive series for the production of plastic products and products that combine plastic with other

Materials

Accompanying the mold development process

Mold development is a stage where expertise in plastic injection is required. This expertise enables optimization of the design process by examining factors such as: material entry, product extraction, hot grout, surface quality, refrigeration, side carts, types of steels, enclave quantity, double injection and more.