Plastic Prototype

Inox Cast Plastic Prototype

Prototyping is very important for product development in every industry for determining whether your production effort is successful or not. It also helps in determining disadvantages, shortcomings, or defects of your new products. If you need plastic prototype for your business, choose Inox Cast as your manufacturer.

At Inox Cast, we have more than 20 years of experience in providing customers with the best quality and affordable plastic prototype. We offer competitive price plastic prototype production since plastic materials are easy to process, possesses excellent maintainability, and low melting temperature.

Aside from that, plastic prototype offers durability. It has excellent friction properties, fatigue strength, and better stability. Plastic prototyping at Inox Cast is also well-developed. We offer professional injection molding services through our plastic prototyping.

As a professional manufacturer, we offer different types of plastic prototyping. It includes casting techniques, 3D printing, rapid injection molding, and CNC machining. Inox Cast is committed to giving you the best prototyping services through innovation.

Advantages of Inox Cast Plastic Prototype

• Create various versions of your plastic products with different shapes, finishing process, surface textures, and colors
• Demonstrate a physical model of your product to your customers
• Improves the feature, dimension, and appearance of your plastic product
• Easily reduce and identify design flaws, thus, saving money and time

Inox Cast offers plastic prototype solution for different applications like kitchenware, household appliance, automotive parts, industrial parts, electric, and more. If you need a plastic prototype services for your plastic products before production, choose Inox Cast. Just email your 2D/3D drawings.

Get your plastic prototype project at Inox Cast. Contact us for a free quote!

Plastic Prototype: The Ultimate Guide

Plastic prototype plays an integral role in injection molding process.

This guide explores all the fundamental aspects you need to know about plastic prototyping before injection molding process begins.

So, before starting you next project, read this guide.

1. What Is A Plastic Prototype?

A plastic prototype is functional representation of the finished product used for design evaluation and testing.

Plastic prototypes are also used for assessing and detecting problems in the design before going into full production.

plastic prototype

2. Benefits Of Plastic Prototype?

Plastic prototypes allows you test the functionality and performance of a particular design before mass production.

Plastic prototyping has a lot of benefits.

The main ones are as follows:

Discovery Of Problems

Plastic prototypes help with early detection of problems in the design.

Detecting mistakes early can help prevent major problems later in the production phase. This definitely helps with waste and cost reduction.

Estimation Of Lead Time, Production Cost And Materials Requirements

Plastic prototyping helps you calculate the amount of time you will need to produce a single part.

It also allows you to calculate the approximate amount of money you will use in the process.

With an elaborate cost estimation you can start raising funds or look for investors.

Helps In Estimation Of Material

Plastic prototyping also allows you to estimate the amount of material you will need so that you do not run out of material mid production.

It also helps determine the quality of the materials used and whether they can with stand wear.

Select Prototyping Method And Equipment Required

Plastic prototyping can help you identify which method is best suited for your needs.

It also helps determine if the existing equipment can be used for production.

This helps you know if you need to make any adaptations or buy new machinery all together.

Better Way To Get Customer Feedback

Plastic prototypes provide the market feedback. If there is positive feedback you can go ahead with mass production.

If otherwise you can make a few adjustments to suit what the consumers prefer.

3. Methods Developing Plastic Prototype

Some of the main techniques include:

CNC Machining Plastic Prototypes

CNC machining one of the methods of developing functional plastic prototypes.

This technique offers great mechanical quality as well as a wide range of thermoplastics.

It involves carving out a 3D model from a solid block of plastic material using different size tools.

For this process fabricators use a digital milling machine which usually has three axes which are controlled digitally.

CNC machining

Here, the whole process is automated as the working of the machine is controlled by a computer.

The computer usually directs the machine using a 3D file.

CNC machining is ideal for creating single- use plastic prototypes to be used in functional testing.

Remember, the technique is efficient for creating not more than ten prototypes.

Note that CNC machining is quite different from other methods as it does not require a mold. As a result it is very cost effective.

In comparison with other methods, CNC machining offers more potential for more surface finishes, tight tolerances, threads and undercuts and less size limitations.

Vacuum Casting Plastic Prototypes

With this method, fabricators start by producing the design into a master model. They can do this by either 3D printing or CNC machining.

This method makes use of the vacuum effect.

During the manufacturing of the prototype, fabricators inject the material into a mold made of silicone.

This is why vacuum casting is sometimes referred to as silicone molding.

vacuum casting

This method is a fast way of developing plastic prototypes as each silicon mold produces around 25 prototypes.

Also, the average turnover time for this method is two weeks.

This method is ideal for plastic prototypes that serve as visual models and not any mechanical purposes.

Vacuum casting is compatible with a wide range of materials whether transparent or opaque or in other colors.

Prototypes made by vacuum casting are high-precision with very fine details.

This is because silicone mold allow creation of prototypes parts that are identical to the finished product.

Vacuum casting is perfect for complex designs.

Injection Molding Plastic Prototype

Injection molding is ideal for highly limited production runs. It allows fabricators to develop high quality plastic prototypes in a short time.

This method involves injecting heated plastic resin with a force into a metal cast. It is then cooled rapidly into a solid part.

So, the result is a plastic prototype with great mechanical properties as well as a high quality surface finish.

injection molding

Plastic injected mold prototypes give reliable information on the requirements for a full production run.

They might also provide insights on mechanical properties and operation of your product.

In short plastic injected mold prototypes are real life replicas of the finished part.

There is wide range of plastics used for injection molding; PC, PP, ABS, Nylon, HIPS, etc.

With the right material plastic prototypes can possess the mechanical properties and robustness of the product.

3D Printing Plastic Prototype

3D printing is also known as additive manufacturing. It is actually a blanket term that includes a few manufacturing technologies.

The most common for producing plastic prototypes are stereolithography (SLA), Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS).

Stereolithography (SLA) is an ideal plastic prototyping method for creating single units. It is also excellent for producing plastic prototypes with complex designs.

SLA is an additive process. It involves adding sequential layers of photosensitive resin. Fabricators use a machine to add these layers.

A computer usually controls the machine. The computer commands a UV laser to start solidifying the liquid material.

Fused Deposition Modelling (FDM) takes advantage of the extrusion process. Plastic material is deposited in a layer-by- layer style until the final prototype is created.

Depending on the type of materials the fabricators use, plastic prototypes made by FDM are strong and have high resolution.

FDA can be used on a wide range of plastic materials.

SLS technology uses a high powered laser to sinter powder into a 3D plastic prototype. Sintering is a process whereby powder is fused using high temperatures.

Print quality and material for SLS is superior to that of FDM.

Plastic prototypes created by this technique are more durable, functional, and flexible and have a higher resolution.

3D Printing

3D printing is ideal for producing low volume plastic prototypes with quick turnover times. This method helps fabricators cut down on prototype develop time.

4. Uses Of Plastic Prototype

Uses of plastic prototypes include the following:

Design testing and evaluation- this is the main use of plastic prototypes.

A plastic prototype makes it possible to have a real version of the final product.

This way you decide which aspects of the design are worthwhile and which ones need to be removed or revised.

Survey- plastic prototypes can be used to collect data. You can conduct a market survey and get customer feedback.

The market feedback can help you determine whether to go ahead with mass production or make changes.

Pitching-plastic prototypes can be used to showcase your designs to potential investors of clients. You can also use them to introduce your ideas.

5. Considerations Before Fabricating Plastic Prototype

Before fabricating a plastic prototype, it is essential to select a prototyping method that is best suited for your application.

The following are key factors you should consider before fabricating a plastic prototype:

Purpose Of The Prototype

The first consideration should be the application of the plastic prototype.

Your prototype might be for functional or non-functional testing, marketing or sale.

In this case you should choose a prototyping method that will produce your prototype parts according to your requirements.

Be it the color, geometrical design or the surface finish.

Volume And Cost

The size and volume of the parts are a main determinant in the final cost of the fabricating process.

Besides, the amount of plastic prototypes you wish to produce will help you determine both the method and material to use.

The cost of producing plastic prototypes varies with each technique.

Factors such as labor costs, automation, cycle times, set up and tooling cost can affect the price of a prototyping method.

Ensure to select a method that coincides with your budget as well as your volume requirements.

Material

When selecting a material for your plastic prototype you need to consider a number of factors.

These factors include functional requirements, cost, aesthetics, mechanical properties, etc.

You need to consider the requirements for your prototype and choose the optimal material.

Lead Time

Prototyping methods have different lead times. How quickly you need your prototype will help you determine the best suited technique.

Some prototyping methods have quick turnover times; as quick as 24 hours. Others are slow and can take up to 2 or 3 weeks.

Therefore, if you need your plastic prototype very quickly, you should consider a method that produces them rapidly.

Form – Before starting on the fabrication of a plastic prototype you have to consider the complexity of your design.

How complex is you design? Does it include complicated internal features or tight tolerances? Answering these questions can help you determine the most suitable prototyping technology.

You need to select a technique that will effectively comply with the design of your plastic prototype.

6. Choosing Materials For Plastic Prototype

When it comes to plastic prototypes, it is critical to choose the most appropriate material.

Plastic materials differ in properties such as durability, flexibility, strength and appearance.

When choosing a material for your prototype it is important to consider the following factors:

• Manufacturing process; 3D printing, CNC machining or injection molding.
• Intended purpose of the plastic prototype or the expected mechanical functions.
• Cost
• Amount of prototypes required
• Time

The most common materials for plastic prototypes are as follows:

ABS (Acrylonitrile Butadiene Styrene) – this is a very strong material with a good quality surface appearance.

Its appearance can be also enhanced further by painting, metalizing and decorating to achieve your desired look.

ABS is suitable for use in all prototype processes. It has excellent impact resistance, it’s easy to machine and thermoform.

Polypropylene (PP) – this material is ideal for plastic prototypes that require flexibility. It is crack and stress resistant.

It has a high chemical resistance as it does not react with most substances.

The downside to this material is that it is hard to paint the surface or glue it. PP is ideal for making injection molded plastic prototypes.

Polyoxymethlyene (POM) – this material has low friction and exhibits very good wear resistance.

This makes it ideal for specific prototype parts such as gears and other moving parts.

POM is a strong and very dimensionally stable; up to temperatures of 180F.

Polycarbonate (PC) – this is one of the strongest plastic materials available. It is clear and provides a certain degree of flexibility.

The challenge with PC is that it is not scratch resistant and it is difficult to glue.

When choosing PC as a material for your prototype you need to consider its application carefully.

Nylon (polyamides) – this material is ideal for prototypes that require high strength, chemical resistance and durability.

These properties combined with others such as impact strength, high heat deflections and abrasion resistance make nylon suitable for industries such as marine and aerospace.

Furthermore, there are formulations of nylon in both glass reinforced and natural grades.

These offer different levels of properties such as strength, thermal resistance and stiffness.

Photo-curable Resins– these are made from acrylic bases or epoxy.

Materials are suited for prototypes whose main aim is to prove and test out a design quickly.

This is because photo-curable resins are reasonably priced and they allow for fast production.

Acrylic (PMMA) – this material is clear, strong and scratch resistant. It has a glossy surface appearance.

Acrylic is most suitable for transparent plastic prototypes such as optical products, light pipes and automotive lenses.

7. Types Of Plastic Prototypes

Visual – A visual plastic prototype provides a clear idea of how the finished product will look like.

This type of prototype does not necessarily need to function as the final product would.

Also, the quickest and least expensive method to develop a visual prototype is by 3D printing.

Functional – A functional plastic prototype is designed to be almost identical to the final part. From the material, surface finishing to the mechanics of the final part.

Functional plastic prototypes allow you to test the design of your product before moving on to the production stage.

They help you identify any mistakes or miscalculations in the design so that the final product is perfect.

Functional prototypes also allow you to test the material in terms of strength, flexibility, durability and other mechanical properties.

Working prototype – This type of plastic prototype represents almost all the functionality of the finished part.

A proof-of- principle plastic prototype – This type of prototype allow fabricators to verify some particular aspect of the design.

However, this prototype does not usually possess the functionality of the finished product.

A user experience plastic prototype – Type of prototype is used for user research. It represents both the function and appearance of the product.

8. How Plastic Prototype Compare To Finished Plastic Parts

Plastic prototypes and finished parts differ in the following ways:

Material

The materials used for finished parts may be more expensive and harder to fabricate.

Plastic prototypes are usually made of inexpensive and readily available material.

Production Method

Mass production procedures are usually not suitable for making low volume parts.

This implies that plastic prototypes may be created using different fabrication methods.

plastic prototype

For instance, the final parts may be made by plastic injection molding. This means they will require a custom tool which can be expensive.

Plastic prototypes on the other hand can be made simple and inexpensive fabrication methods such as 3D printing.

Verification

The finished plastic parts are subject to numerous quality assurance procedures.

Also, the purpose of these assurance tests is to ensure that the final part conforms to the specifications and drawings.

These tests may include quality assurance, inspection features and statistical sampling methods.

finished plastic parts

Plastic prototypes on the other hand may be exempted from majority of the verification tests.

This is based on the fact that prototypes are not final products and adjustment can always be made during the mass production.

9. Factors Determining Plastic Prototype Cost

Some of the main factors:

Materials Used

There is a wide range of materials that are used to create plastic prototypes. These plastic material have different prices.

Plastics such as PP nylon and lean towards the less expensive side while thermoplastics such as ABS and PC can be quite expensive.

Complexity Of The Design

If the design of the prototype is complex, then it is likely to be expensive. If you wish to reduce the cost, you can simply the design.

Large and simple design prototypes are usually cheaper than small land complex ones.

Custom and complex designs require more time and machining to create making them costly than simple ones.

Method Of Fabrication Used

3D printing is the most affordable of the prototyping methods. CNC machining is quite costly but not as much as injection molding.

With injection molding however, the price goes lower as the volume of production increases.

This is no different from the other prototyping techniques as they too are affected by the volume required.

Related Resources:

Plastic Prototyping

Plastic Extrusion

Plastic Thermoforming

For all your plastic prototyping, contact INOX now.