Design and engineering play a significant role in creating products that function as intended for the expected lifecycle or beyond. It doesn’t matter if your parts are injection molded or machined; creating quality parts requires in-depth material science, knowledge of manufacturing processes, mechanical engineering, tooling design, and dimensional tolerancing. With so many variables, it’s no wonder companies struggle. Ensinger’s Design and Engineering Services can relieve you of the uncertainty of not knowing if every variable has been accounted for. We’re here to share our expertise and knowledge to help turn your idea into a successful reality or to assist you in overcoming any current component challenges.

Companies using this service effectively can expect to see shortened product launch cycles, fewer returns and warranty claims, and reduced total costs. Here, we will walk you through the different phases of our Design and Engineering Services.

Application Material Selection

One of the most important decisions to be made is material selection. Improper material selection can result in issues ranging from manufacturing and assembly challenges to catastrophic part failure in the field.

Remember that some plastics are more amenable to one manufacturing process or another. For example, machining can produce heat that can create tolerance issues with plastics with a high coefficient of linear thermal expansion. Thermosets like Torlon require special considerations when injection molding. Ensinger can help guide you to the manufacturing method that will work best for your parts.

There are many factors to consider. Some questions to be prepared to answer include:

  • Application Requirements
    • What is the intended function of the product (e.g., load bearing, insulating, impact resistance)?
    • What are the performance demands (e.g., strength, durability, electrical conductivity, chemical resistance, self-lubriating)
    • Are there any size, shape, or weight constraints (for example, small, thin-walled parts require high-flowability plastic or products requiring lightweighting require high-strength, low-density plastic)?
  • Operating Environment
    • What temperatures will the product be exposed to (intermittent, continuous use, and peak exposure)?
    • Will the product face thermal shock or high thermal expansion or need to retain dimensional stability under temperature fluctuations?
    • Is the product exposed to moisture, humidity, or submersion? Does it need low water absorption or resistance to hydrolysis?
    • Will the product face chemical exposure (solvents, oils, acids, UV, ozone, etc.)?
    • Does the material need to be electrically conductive, insulating, or dissipative?
  • Material Compatibility
    • Will the part be in contact with other materials (e.g., plastics, metals, adhesives, petroleum products, or oils)?
    • Are there concerns about galvanic corrosion in adjacent metals, chemical reactions, or material degradation?
  • Performance Over Time
    • How long does the product need to last under normal use?
    • Will the material face cyclic loading, stress relaxation, creep, fatigue, or impact?
    • Does it need wear resistance, abrasion resistance, or friction control?
    • How will long-term UV, oxidation, or thermal aging affect performance?
  • Regulatory and Safety Mandates
    • Does the material need to meet FDA, UL, RoHS, REACH, or automotive/medical regulations?
    • Are there flammability, smoke, or toxicity restrictions?
    • Is the material required to be food-safe, medical-grade, or compliant with environmental health standards?
  • Cost Constraints
    • What is the budget per unit?
    • Are you open to lower-cost alternatives that still meet requirements if available?

Part Design And Function

Once the material selection and manufacturing method are determined, part design can begin. Preliminary part design may begin with concept sketching that outlines the basic shape and pat features. It is important to consider the manufacturing method when designing the part, as each process has different constraints and design considerations.  For example, wall thickness. Injection molded parts require uniform wall thickness to avoid sink marks and warping, while CNC machining can handle variable wall thicknesses.

CAD And Manufacturing Drawings

Computer-aided design (CAD) and manufacturing drawings are critical components of product manufacturing. Once the initial design concept is validated, the next crucial phase in engineering services for plastic products is the creation of CAD models and manufacturing drawings. This step bridges conceptual design and actual production, ensuring the part is manufacturable, meets functional requirements, and aligns with the chosen manufacturing process (e.g., injection molding or CNC machining).

Finite Element Analysis

Finite Element Analysis (FEA) is a simulation method used to evaluate a part’s performance under real-world conditions by analyzing stress, strain, thermal effects, and other forces. By breaking the design into smaller finite elements, FEA predicts weaknesses, identifies potential failure points, and helps optimize the structure before physical prototypes are made. This process is especially valuable for plastic components, accounting for material properties such as flexibility, impact resistance, and thermal expansion. Integrating FEA early in the design phase reduces the risk of costly revisions, ensures the part meets performance requirements, and enhances durability while maintaining manufacturing feasibility.

Design for Manufacturability Review

Design for Manufacturability (DFM) ensures that a part is designed with manufacturing capabilities in mind, optimizing it for efficient production while accounting for how specific plastics behave during the process. This approach helps identify potential challenges early, such as warping, shrinkage, or material flow issues, reducing the need for costly modifications later. By refining the design to align with the strengths and limitations of manufacturing methods like injection molding or CNC machining, DFM minimizes defects, improves consistency, and streamlines production. It also plays a key role in cost reduction by eliminating unnecessary complexity, optimizing material usage, and enhancing cycle times, ultimately leading to a more reliable and scalable final product.

Prototype And Testing

After the design is complete, the next steps involve prototyping and testing. Prototyping is creating a test part that is not meant for commercial release and helps define the design, materials, and fabrication criteria for the new product. This process may include several iterations to finalize the design of the commercial part.

The first prototypes may be just to assess the size and shape and may or may not be made from the final material. As the prototype progresses, it is assessed for form, fit, function, and how it fits within the assembly. Once the prototype is acceptable, parts can move on to production.

Why Choose Ensinger for Design and Engineering Services?

With years of experience helping companies design and manufacture products for both injection molding and CNC machining using both thermoplastics and thermoset materials. Our highly skilled in-house engineers have all the tools and skills to ensure your product can be manufactured efficiently and cost-effectively while meeting all your requirements. Contact us to learn more.