injection mold

12 Steps for injection molding production

Depending on the branch of industry, a drawing office will carry out very different types of work. An organization with a ‘design and make’ nature generally follows a plan that establishes stages in the injection molding development process, from the time a client inquires to the delivery of the finished injection molded product. Many of the activities associated with a plastic product are determined by its function.

There is a good chance that a vehicle manufacturer will not design and manufacture all the parts, but instead subcontract them out. The engine is composed of electronic and mechanical components that must meet predetermined specifications. It is also important for them to be designed to be installed in defined areas and to be suitable for operation under clearly defined circumstances. Component manufacturers are committed to improving the performance and quality of their injection molded products together with the end-users.

A typical, step-by-step description of the stages of design and development for injection molded components in this category is given below:

  • Step 1

Clients seeking a particular plastic product are often not familiar with all of the details and are therefore in need of the professional experience and advice of a specialized plastic producer to clarify their initial thoughts. In such a situation, if a range of viable options is presented, opinions will be focused and decisions will be made with greater certainty.

  • Step 2

An injection-molded engineering company’s Chief Engineer or Design Authority must produce the specifications for its molded products, including all applicable legislation that the product must comply with, and the level of configuration control a product must maintain throughout its life cycle. There is no doubt he will seek advice when he is confronted with aspects of the plastic injection molding design that he does not understand or where technology is involved on the fringes of the design.

The company must, however, carefully prepare a top executive plan because at the outset the organization must decide whether it wants to entertain or participate in proposals for achieving client satisfaction. In the current job market, while the firm may reap great rewards, it may not be able to meet its financial and labor needs and deliver on its commitments. Perhaps they do not wish to take the risk, and given their available production capacity, they prefer not to bid on a potential order.

  • Step 3

It is important to consider these drawings as provisional at this stage. As a plastic part of this exercise, specialists within the organization contribute their views so that feasibility can be assured.CAD (computer-aided design) is extremely useful as part of this preliminary stage. In the system, any information that can be defined mathematically is stored and displayed. Following the establishment of the basic geometry, design variations can be kept, and sections of previous proposals that were found to be satisfactory can be continuously used in redrawing the alternatives. It is possible for the designer to take a printout at any point in the injection molding development process so that others can offer suggestions and comments. An important consideration at this stage is determining the level of configuration control. Lots of times, the reasons for and against taking a decision (Optioneering) need to be recorded formally.

A firm order must be accepted at a later date so that the company understands the extent of its commitment. As part of this commitment, not only must you have the technical ability to design and produce an excellent product, but also the financial abilities to implement the product on the production line.

plastic part design

  • Step 4

Preliminary design work will yield a concept, which must be approved by the customer before it can be implemented. It is important for us to confirm with the client what dimensions and operation parameters are expected to be included in a large assembly involving our product before spending money on development.

  • Step 5

Working drawings will be developed if everything is in order. As a company, we have merely ensured that our proposals are in line with the requirements and that hopefully, we will be able to satisfy the customers based on these drawings – they are not production drawings. At this point, we must prepare working drawings for the purpose of formulating construction methods.

In order to ensure that all design requirements are being incorporated in an economic manner, and to guarantee supply going forward, a design review is required.

  • Step 6

A prototype or a small batch may now be manufactured. The ultimate injection molding production methods of manufacture will not be employed here. For example, components that may be molded could be machined from solid to eliminate casting costs.

  • Step 7

Test prototypes are carried out to ensure that the specification’s operational requirements are met. This may lead to design changes. In addition to extreme temperatures and humidity, product tests are often conducted when the component is exposed to shocks, vibrations, and fatigue.

The validity of these tests can only be confirmed by proven test results.

Reviewing and analyzing the design at this point will ensure that the progress in every technical aspect and for each team member will be acceptable.

  • Step 8

When the performance targets from the prototype have been confirmed, the production drawing can begin. Modifications will be made to the prototype drawings so that full-scale production processes can be used during manufacture. The process of loading the plant and moving work through the factory needs to be planned in order to make sure that plant is used efficiently. It is now time to begin the necessary paperwork.

  • Step 9

Following the production of the prototype, different manufacturing methods were employed to make the final plastic injection molded product. To ensure the specifications are not compromised, this should be verified beforehand.

  • Step 10

Detailed specifications can be released for full-scale production after the equipment is tested in its operating environment and its performance has been thoroughly tested.

  • Step 11

Machines are not the only tools used in the production process; jigs, fixtures, tools, gauges, inspection procedures must be planned, as well as auxiliary equipment for moving materials on and off the production lines.

  • Step 12

Occasionally, teething problems arise, and samples are taken to ensure that all plants and equipment operate as expected. A full-scale production cannot begin until downtime has been eliminated.


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