How to develop a new plastic product for Plastic Injection Moulding Manufacturing

The use of plastic in manufacturing is constantly growing as it is a primary component of most consumer articles. This will not change soon. It is mainly the initial designer of a products responsibility to ensure that their product is designed in such a way to be environmentally friendly or recyclable where needed. When someone has a new and innovative idea for a plastic injection moulded product, there is a few very important aspects that one must keep in mind before contacting a PIM to assist in developing a new mould and moulding the final product.

Below are a few aspects to have in place before you contact a local plastic injection moulder, like Dela Plast who can assist you from design of the product right through to production.

Need help with actioning your next big idea?

Dela Plast is a plastic injection moulding manufacturer in Pretoria, South Africa. We specialise in contract injection moulding for special parts, which means we supply customers their unique products, of which the customer owns the mould. We get many pricing requests from enthusiastic customers for new products or components they require. Unfortunaltely their amounts do not suffice a the costs of a new mould.

Purchasing a new plastic component is not as easy as just placing an order. A LOT of work and thought goes into the initial product design, that is not always foreseen when a great idea is conceived. But through proper design and planning, mould and production costs can be reduced, and a high quality product supplied to the end consumer.

We advise you on your product development process:

One of the main problems is that a client does not always know how to go about in developing their new idea or what the costs involved is. One of the biggest hurdles in plastic injection moulding is the costs of the moulds. Moulds need to be made of high quality tool steel to resist the impact of the pressure of the heated plastic that goes through the tiny components(gates), to fill your mould for uniform end products.

But before we get ahead of ourselves lets look at the steps for plastic product development:

10 Steps for manufacturing a new Plastic Injection Moulded product:

1. Acquire a great, unique product idea which is feasible and will sell tens of thousands of parts. It is very important to have a high production rate to make the idea feasible for your market.

2. Complete the design for the product with correct dimensions and weight, keeping in mind important factors like material choice, uniform wall thickness, avoiding sharp corners etc. Planning is very important to prevent costly mistakes by thinking the design through. Ideally have a 3D drawing of the product to send the PIM.

3. Find a local plastic injection moulder and have a brainstorming session regarding your design. Discuss the technical aspects of the product like the number of cavities necessary for optimum production, the amount of moulds needed for the different components, or if family moulds ( more than one part in a mould) could be an option. Also discuss the raw material to use and product manufacturing time. Product assembling, packaging and transport are important aspects that they would be able to assist with.

4. Improve and finalize the design from what you have learned from the professionals. Preferably print a sample by 3D print technology to ensure that you are happy with the end product and that it works for the intended use. The production price per unit will be quoted by the plastic injection manufacturers. They will also have the right contacts for good mould makers to request a mould quote from.

5. Sign off the design with the mould maker and pay the deposit for making the mould. The mould making normally takes around 12 weeks depending on the type of mould required.

6. The mould is now tested for accuracy and functionality. A quality check of your brand new product, should follow to confirm that you are happy with the end product. The PIM looks out for flashes, short moulding, burn marks, vacuum voids and sink marks to ensure a high quality product.

7. Final delivery to the plastic injection moulder where production will be done, takes place. Remember to esure your mould. Dela Plast ensures their clients moulds in our factory.Some last checks and amendments can be done by the mould maker if necessary, but note that no large changes can be done when a mould has been completed. That is why the testing of a 3D product is so important.

8. Place your orders by specifying materials, colours, amounts and delivery times. Keep in mind that Dela Plast runs 24 hours per day, so small, regular orders will cost more than large once off orders, as mould setup time is included in product cost.

9. Production takes place according to order in the lead time discussed. Assembly can take place in the factory if necessary. Products are then packaged as specified by the client.

10. Delivery of end product takes place. Depending on what the product/ component is, you can now utilise it or sell it as intended.

Are you excited yet? Let us help you get started.

From the above steps you can see the importance of gaining the correct technical and professional knowledge as well as doing the correct planning and having sufficient budget for a product. The success lies in implementing all these above aspects and insights to get to your final quality plastic product.

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