Plastics are one of the most popular materials used to produce end-use products and parts. They can be used for everything, from consumer goods to medical devices. Plastics can be used in many different ways. There are thousands of options for polymers, each with its own unique mechanical properties. How are plastic parts made?
To cover a broad range of applications, part geometries and types of plastics, a variety of plastic manufacturing processes has been created. It is crucial for engineers and designers working in product design to understand the current manufacturing options and new developments.
This guide will provide an overview of the most popular Plastic manufactures used to produce plastic parts. It also contains guidelines that can help you choose the right option for your particular application.
How to choose the right plastic manufacturing process
When choosing a manufacturing method for your product, consider the following:
Form Are your parts complex or have tight tolerances? Manufacturing options can be limited depending on the design of the part. They may also require significant design optimization (DFM) to make them economically producible.
Cost/volume: How many parts are you planning to make each year? While some manufacturing processes are expensive to set up and tool, others produce low-cost parts per-part. Low volume manufacturing processes, on the other hand, have lower startup costs. However, because of slower cycle times and less automation, cost per piece remains constant or drops marginally as volume increases.
Lead Time: How fast do you need parts made or finished goods? While some processes produce first parts in 24 hours, others take months to set up and tool for high-volume production processes.
Material: To what stresses and strains must your product be able to withstand? There are many factors that determine the best material for a particular application. It is important to balance cost against aesthetic and functional requirements. Compare the best characteristics to your application with the options available in the given manufacturing process.
Different types of plastics
Plastics are available in thousands of different varieties, with many base chemistries, derivatives and additives. These Plastics Dealers can be formulated to provide a wide variety of aesthetic and functional properties.
Let's first look at the two main types thermoplastics and thermosets of plastic to simplify the task of choosing the right material for a particular part or product.
Thermoplastics
The most widely used plastic is thermoplastics. They can withstand multiple melt and solidification cycles without causing significant degradation. Most thermoplastics come in small sheets or pellets that can be heated and shaped using different manufacturing processes. This process can be reversed because there is no chemical bonding. It makes it possible to recycle or melt thermoplastics.
The most common types of thermoplastic material:
Acrylic (PMMA).
Acrylonitrile butadiene styrene (ABS)
Polyamide (PA).
Polylactic acid (PLA).
Polycarbonate (PC)
Polyetherether ketone (PEEK).
Polyethylene (PE).
Polypropylene, (PP)
Polyvinyl chloride (PVC)
Thermosetting Plastics
Thermosetting plastics, also known as thermosets, are permanent solids after curing. This is in contrast to thermoplastics. The curing process is inducible by heat, light or other suitable radiation. This causes polymers in thermosetting materials to cross-link. This curing process creates an irreversible chemical link. Thermosetting plastics melt when heated and then decompose upon cooling. It is impossible to recycle thermosets, or return the material to its base ingredients.
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