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Taizhou Union Plastic Mould Co.,Ltd

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From The Design Of The Mold To The Production Of Finished Products, Every Step Is Taken
Dec 10, 2018

Mold design is an important link in the process of large-scale product research and development. Since product and mold design are interdependent, it is very useful for product design engineers and mold design engineers to understand the development process of plastic parts, mold design process and the role of mold manufacturing process. Typical product development processes take place at various stages, including: product definition, product design, experience and product development, capacity improvement, and marketing.

Despite the complexity of product development processes, most have the following two key attributes:

1. Establish a systematic development plan to ensure the perfection of design and manufacturing.

2. Effectively evaluate and allocate the budget at key points of the project, so as to establish the checkpoint process to avoid risks.

3. The product development process is divided into multiple stages through the approval fee level. The next stage evaluates the previous stage

1. Product definition

The product development process starts from the market analysis, the understanding of competitors' product standards, the definition of product specifications and the evaluation of potential profits. If management agrees to develop new products, a suitable team will be formed for early conceptual design and business development. In the first phase, you need to estimate the approximate size, attributes, and cost of the product. Conceptual sketches, physical prototypes, and prototypes may also be discussed and evaluated for feasibility.

In terms of profitability, market research will try to predict potential sales at different price points during the early stages of product calenders. At the same time, will establish the development of products and products to market the human cost and project cost budget. Evaluate the concept design, anchor expectations and budget of the croucher by continually evaluating the potential for commercial success of product development. The proposed product development project may be rejected, shelved, or modified accordingly

2. Product design

If the project is approved and a budget is allocated, the product development process continues, usually with additional funding followed by further analysis and design. In the second phase, each component in the product is designed in detail. The design of plastic parts includes consideration of aesthetic, structural, heating, manufacturing and other aspects. The design of the manufacturing method will be used to identify problems with effective component manufacturing. The design of the assembly method can be used to reduce components, determine critical dimensional tolerances and ensure the assembly economy of finished products.

The design results of the initial product design phase (as recommended by the second management level) are a detailed and validated product design. "Detailed design" means that each component is specified with materials, geometry, surface roughness, tolerances, suppliers and costs. If you need to customize plastic parts, you will need to quote for these parts at this stage. Submit manufacturing cost and detailed design to management for approval. If the design and cost of the product are acceptable, the required budget can be allocated and product development is mainly focused on manufacturing.

3. Business and production development

Although mold design and mold manufacturing is the focus of the plastic industry, but these contents are included in the "mold manufacturing" activities. At the same time, important business development and production planning will be carried out. Specifically, business development needs to fully define the supply chain and establish an initial order to support the launch of the product. Production planning is required to lay out assembly lines, determine human resource requirements, and establish plans for manufacturing technical facilities.

Upon completion of the tooling, production, testing and assembly of the alpha (initial) product will take place. The initial product then goes through a series of tests to verify its performance level, execution criteria, and user satisfaction. If the initial product is not satisfactory, the manufacturing process, associated tools, and detailed component design should be adjusted appropriately. At the same time, the operators will draw detailed instructions for quality control and personnel training.

4. Enlarge and put into production

A high level management review method is used to verify that the design and production plan of the developed product is satisfactory. If so, a medium weight product can be manufactured in the sample production process according to standard manufacturing requirements. The "beta" product produced will be provided to the Marketing Department, sales force and key customers to determine the acceptability of the product. As before, products designed and manufactured may be modified to solve important problems. When all stakeholders (marketing, sales, manufacturing, key suppliers, key customers) are ready, the product is produced on the basis of the sample production process and the initial inventory of the product is established before the product is put on the market

5. Role of mold design

Die quotation, die design and die manufacturing support the huge product development process. When a mold and/or part cost quote is required, it usually means the beginning of the conceptual design phase or the detailed design phase. At this point, if the mold engineer or mold maker gave a full detailed design, then it is not reasonable

The reasons are as follows:

1. A lot of work in the early stage of mold design was carried out simultaneously with imperfect product design;

2. For the sake of manufacturing technology or product performance, the mold design may need to be greatly modified.

The mold development process usually begins with a lack of detail in the initial design, which can lead to unsatisfactory products if used directly. Design information for key parts required for initial die design including part size, wall thickness, and expected production. Based on this information, the mold designer can develop the initial mold layout, provide cost estimates, and provide improvements to the product design. In order to speed up the product development process, mold design and mold parts procurement and customization can be carried out at the same time.

When the product development phase is about to end, the mold manufacturing and debugging phase begins. For this reason, mold manufacturers and suppliers are under great pressure to provide high-quality molds as soon as possible. This task is challenging because of potential errors in the product design process. Therefore, the mold designer may be required to redesign and modify parts of the mold and cooperate with the mold manufacturer to determine whether the mold meets the production requirements