Engineering Services
QUALITY FROM START TO FINISH
PLASTIC PART DESIGN
Nowadays, injection molding is one of the most popular methods of manufacturing plastic parts. They are used in automotive parts, electronic housings, household appliances, medical equipment, bicycles and many others. Designing 3D parts is an essential step in creating a successful product that meets both the manufacturer’s goals and the needs of the final user. It involves balancing technical, economic and aesthetic requirements with the specific requirements of the user. There are several factors that must be considered when designing plastic components to make them possible to launch and to ensure that the injection molding process works properly.
KEY FACTORS INCLUDE:
• material considerations for the intended application (temperature, chemical resistance)
• wall thickness
• draft angles
• corner radius
• gate position
• inclusion of ribs and protrusions
• material shrinkage
• special features (holes, undercuts)
These design features must be considered to produce the best injection molded part. Attention to critical part and mold design details enable us to produce repeatable quality parts. Before beginning your project, we work with you to complete our product requirements and design specifications questionnaire. This valuable document covers key elements including product usage and function.
NEED TO ANSWEAR SOME SAMPLE QUESTIONS:
• How will you use the part? What is its application? Is it a standalone product or a component of an assembly?
• What is the user environment (UV exposure, salt water, corrosive chemicals)?
• Does the part need to withstand specific pressure or impact?
• What is the target weight, dimension, texture, color, and aesthetic design?
The design of a plastic part is the first and most important step in our concept for manufacturing solutions. Our design process and feature checklist are a regular part of our engineers’ work. Attention to critical details of part and mold design enables us to produce repeatable, high-quality components that meet our customers’ requirements and are optimized for success.
WHAT IS MOLDFLOW 3D FOR?
The design of injection molded parts is optimized using injection molding simulation software such as Moldflow 3D. Using simulation during the design phase can help reduce physical mold issues. It allows the designer to modify and re-simulate the design to implement improvements. The mold tool should be designed so that the plastic part slides out easily. Working with an experienced plastic injection molding and engineering team can help avoid many of the issues that may arise during the design and development process. ALKAZ Plastics’ experienced design team understands the importance of this process and works closely with customers to determine product design specifications. By working with customers, we ensure that the final product meets their specific requirements and is optimized for success.
MOLD BUILDING
Engineering success is determined by our ability to maximize success, and we know for injection molded plastics, the engineering and design development process is critical. We’ve found that the two most critical factors for success are partnering with you early on in the design phase and focusing on what we consider the 5 Keys to Success. The following five stages must work together to engineer out cost and engineer in part quality and performance.
5 STAGES:
1. Part Design and Material Selection. Understand the product application, intended market, end-use objective and use environment.
2. Tool Design and Mold Building, Design for mold efficiency, longevity and performance.
3. Molding Process. Review injection molding technologies, cycle times and material flow, and employ scientific injection molding.
4. Quality Systems and Metrology. Focusing on tolerances, part inspection, steel safe mold and more.
5. Automation Systems.
A successful part starts with a well-designed mold. This complex and precise process determines part manufacturability and lifecycle costs, and it takes into account the key components of mold design while adhering to a part’s unique specifications. Proper mold design and mold building will help reduce cost, increase quality and optimize performance. We use the latest CAD technology and software to create a robust mold design, as well as moldflow analysis to evaluate all mold designs and parts prior to development.
HIGH PRECISION
ALKAZ Plastics’ team of mold design experts has decades of experience building custom and technically advanced molds. We produce high-quality injection molding tools using the latest technology for maximum performance and durability. We work closely with our customers throughout the design process to ensure mold design specifications align with product design goals and manufacturing requirements. Our mold design process incorporates the latest technology and industry standards, ensuring molds are optimized for maximum performance and durability. At ALKAZ Plastics, we are committed and focused on meeting the unique needs of your plastic parts production. We will support you through every stage of the design process, then quickly and accurately implement your manufacturing project.
MOLD TRIALS & QUALIFICATIONS
All new plastic injection molds undergo mold trial and qualification to ensure all part dimensions are correct and the mold functions properly. Scientific injection molding is then used to establish consistent and repeatable molding process parameters, which ensures quality parts are produced. All part dimensions are then reviewed for accuracy.
PRODUCT DEVELOPMENT
Start the process of bringing your design to life with us. Turn your 2D sketches into 3D computer-generated models. Our team of CAD and graphic designers have years of experience bringing product concepts to life. The ALKAZ Plastics team is dedicated to product design and development. They will provide high-quality, photorealistic images for marketing and concept testing. Designing a product for production from the start not only ensures quality but also saves our customers time and money. As a full-service development company, we review every aspect of the design, from the smallest component to the plastic casing. We have years of experience designing products for easy production. Our facility’s prototyping services include CNC and 3D printed parts, prototype assembly for testing and short-run production. We produce prototypes for engineering validation. We can also produce a full working model for use at trade shows or demos. Rapid prototyping provides the critical feedback you need to confirm and finalize your product design process.