Part 1: All-Around Process of Custom Plastic ABS Injection Moulding Parts
Customization of ABS injection moulding parts is a step-by-step process from concept to mass production and typically includes the following 7 large steps:
Step 1: Communication of Demand and Confirmation of Concept
This is the first stage for all projects. You (the buyer) need to communicate in full with the injection moulding factory about:
Product application: The purpose of the part, application environment (i.e., whether it needs to withstand elevated temperatures, whether or not it needs to be impact-resistant).
3D model (STP/IGS format): This is the most important input file, which defines the product's shape, structure and size.
2D engineering drawings (in PDF/DWG format): Define major dimensions, tolerances, technical specifications, etc.
Material selection: Ensure the use of ABS. In case any special requirements (e.g., flame retardancy, weathering, electroplating) are necessary, the brand name (e.g., ABS 757) should be included.
Budget and expected output: Is it a low-volume sample production or high-volume mass production?
Step 2: DFM (Design for Manufacturability Analysis)
Your 3D model will be inspected by engineers and optimization recommendations will be made from an injection molding point of view to prevent probable faults. This can be:
Wall thickness optimization: To establish a uniform thickness of walls so that the product does not shrink or deforms.
Inclination of riser: To make it easy for the product to come out from the mold.
Strengthening ribs and rounded corners: Optimizing the structure and preserving strength.
Parting line position: Determines where the mold will open and the possible position of the closing line.
Gate and runner system design: Determines where the plastic melt is injected into the mold cavity.
Step 3: Mold Design and Production
It is the most pivotal， with the longest cycle and most cost.
Mold Design: Based on DFM analysis, the mold designer designs the overall mold structure like the mold core, slider, draft riser, cooling system, and ejection system.
Material selection: Select mold steel based on production volume (e.g., P20, 718H, S136, etc.).
CNC machining/EDM/ wire cutting: Using precision machines to create each component of the mold.
T1 trial molding: Combine the processed parts into a completed mold and conduct the initial trial molding on the injection machine.
Step 4: Mold Testing and Confirmation of Sample
T1 prototype test: Taking the first sample.
Sample testing: Take a comprehensive measurement (potentially with a coordinate measuring machine CMM) and functional test of the sample size, appearance, and structure.
Design adjustment: Any issue in the sample can lead to slight modifications of the product design or the mold modification. The cycle will be repeated several times (T2, T3.), until the sample meets the requirements.
Step 5: Small-scale production and customer verification
After the final mold is frozen (no other adjustments are made), the pilot-run production (approximately 500 - 5,000 units) will be executed. The units will be sent to you with the following reasons:
Assembly test: Test for compatibility with other components.
Marketing promotion: Used to participate in exhibitions, send samples to customers, etc.
Durability test: Conduct long-term functional tests.
Step 6: Mass Production
After the completion of all the verifications, mass production on a large scale will be carried out. The injection molding factory will:
Optimize process parameters: Maintain injection pressure, temperature, and time as constant, etc., to ensure the uniformity of each product of a mold.
Quality Control: Implement IPQC (Process Quality Control), conduct sampling inspection or finish inspections.
Step 7: Post-processing and Assembly (Optional)
Depending on the requirement, it can also include:
Post-processing: such as cutting of water outlet, ultrasonic welding, and embedding thread.
Surface treatment: such as spraying, electroplating, screen printing, laser engraving.
Packaging and Delivery: Package properly and deliver on time.
Contact Information:ZIBO HUIWEN PLASTIC
[Contact Person's Name] Kama
[Phone Number] 008615069372818
[Email Address] sale@hwplasticparts.com
