When it comes time to produce a high-quality plastic component, there are a few considerations to make before the production run.
What materials should I use? Who is the right manufacturer for me?
In this blog, we’ll look at the five steps to produce high-quality plastic components, key questions to consider before production, and how Agape Plastics is a trusted and reliable manufacturer in this space.
Knowing Your Materials for a High-Quality Plastic Component
In order to create high-quality plastic components, you have to start off with your base material. The two most common materials used are steel and aluminium. These two materials offer their own set of advantages when creating the mold.
Mold Materials
Steel can withstand incredibly high pressure, it’s very durable, but it has a higher melting point than aluminium, making the production process a bit longer.
Aluminium is the other most commonly used material when creating high-quality plastic components. It’s a much more cost-effective material, making it a good selection for a large volume order or for a single prototype. Aluminium isn’t as dense as steel, which has its pros and cons. It’s easier to shape into its designed mold and if any repairs are needed, the turnaround time is very minimal. Inversely, aluminium is more likely to incur defects because of its density relative to steel.
Once the mold selection is made, there are a multitude of plastic options available. Like mold materials, different types of plastics have different applications.
Component Materials
There are a wide variety of plastic materials to choose from. Knowing how each material works and what it’s best intended for, however, makes all the difference. The most commonly used materials have multiple applications.
Commonly used plastic materials include polyethylene, polypropylene, polycarbonate, polyvinyl chloride, and thermoplastic olefins. These five materials all have similarities and differences, but the common unifier is they are cost-effective and provide varying levels of durability.
Which Material is Best for Your High-Quality Plastic Component Order?
Mold Material Applications
Stuck between steel and aluminium for the mold? While the materials have their own defining characteristics, picking one over the other could be the difference between a good product and a great product
Steel has a longer service life because of its durability as a product. While it can last longer, it takes longer to manufacture because of its natural strength.
Aluminium might have a shorter lifespan as a material and over time can have deformities that either need replaced or repaired. However, because it is easier to mold, you can create more high-quality plastic components in a single production cycle.
Plastic Material Applications
It’s one thing to know what plastic materials can be used to form the product. It’s another to know which material is best for your product. Part of that is knowing the intended use of the product.
Polyethylene is naturally a very flexible material making it a strong selection if a product’s design is very intricate and complex. Polyethylene is also extremely durable and can withstand many different environments. An example of a final product made with polyethylene is a bottle cap or a plastic bottle.
Polypropylene also provides incredible durability and is known for its weather and chemical resistance, making it a great selection for any outdoor project or underground. Polypropylene is used to make many automotive parts including bumpers and door panels.
Polycarbonate is often noted for its strength as a product. It is naturally stronger than many other plastic choices, which gives it a long service life. Its strength lends itself to high impact resistance and durability. An example of a product made with polycarbonate is insulating panels.
Polyvinylchloride is one of the most sought after plastic materials because it can work well in multiple environments. It is also an extremely cost-effective material. The most common examples of products made with this material are blood and IV bags in the medical field.
Thermoplastic olefins offer a rubber-like flexibility, making it a strong selection if a customer has a detailed and specific design. This material is also very cost effective. Thermoplastic olefins are often used to create plastic silverware.
Process for Developing a High Quality Plastic Component
The design process starts off with choosing the mold and component material. Once the materials have been selected, our team goes through the design specs with the customer to ensure proper measurements before production.
Material preparation is the part of the production process where resin pellets are fed into a machine and melted into the desired shape. Quality management is crucial in this step of the process, as the right amount of material has to be placed into the machines and the design needs to be accurate.
Once the resin has hardened, injection can occur. The plastic injection hardens around the mold, taking the desired shape. This occurs at very high temperatures ranging from 150-180 degrees Fahrenheit, but can vary depending on material selection. Next, the product is cooled — air chilled or water cooled.
When the high-quality plastic component has cooled, the mold opens and the product is finished.
How to Find the Right High-Quality Plastic Component Manufacturer for You
It’s important to know your materials and the process, but what’s even more important is working with the right manufacturer.
Certifications are an excellent starting point when looking for the right manufacturer. Agape Plastics holds an IATF 16949 certification, which ensures quality management of injection molded plastic components for trim and attachment insert bolts. We are also ISO 14001 certified, which means we have quality environmental management. This means we keep our carbon footprint to a minimum and our customers get the most out of their designed product.
Certifications are the starting point, but history is also indicative of success. For over 50 years, Agape Plastics has been an industry leader in producing plastic components.
Contact Agape Plastics for Your High-Quality Plastic Components
Agape Plastics has been hard at work for you since 1973, delivering quality products for multiple industries. If you’re in need of a high-quality plastic component, connect with us today to see how we can make a difference for your next project.