Plastic parts machining is an accurate and secure manufacturing process that is used to create highly detailed, intricate parts. This process consists of various steps, including engineering and design, production, quality assurance, and fabrication and assembly. Let’s review each of the steps of plastic parts machining in detail.

Plastic Parts Machining Steps

Engineering and Design

The engineering and design process can be lengthy, as it is required to start production. During this process many steps occur and we will review each one:

Material Selection

One of the first things to do during the engineering and design process is material selection. If the improper material is chosen, it can result in issues with manufacturing and assembly or a failure in the product’s application. Your engineer will work with you to review your product’s requirements and help you find the right plastic for your needs.

Part Design

This process starts with concept sketching that outlines the basic shape and features of your plastic part. During part design, it is imperative that you consider the manufacturing method as each method has different constraints that may impact the design of your part.

CAD and Manufacturing Drawings

Both CAD and manufacturing drawings are critical components of the plastic parts machining process. They bring the conceptual design to life, ensuring that the part is manufacturable and meets functional requirements while aligning with the chosen manufacturing process.

Finite Element Analysis (FEA)

Finite element analysis, or FEA, is a simulation method that evaluates performance under real-world conditions. FEA predicts weaknesses and failure points and optimizes the structure before full production can start.

DFM Review

A Design for Manufacturability review ensures that the part is designed with manufacturing capabilities in mind. This optimizes the part for production by identifying potential problems, minimizing defects, improving consistency, and streamlining production.

Prototype and Testing

During this part of the engineering and design process, we create a test part to define the design, materials, and fabrication criteria. This may take a few iterations to realize the right design for the commercial part.

Production

CNC machining is commonly used to create plastic parts, as these methods are highly accurate and can meet the tightest of tolerances. At Ensinger, our team has various CNC machining capabilities, including:

Drilling to machine holes with sizes limited to the size of the drill bit
Broaching to enlarge a drilled hole and improve the quality of the finish
Boring creates a single-point cutting tool to enlarge a hole, and since the tool rotates, the hole size is not limited by the size of the tool
Milling to shape flat surfaces, grooves, and other characteristics into the part using a cylindrical cutter on an axis
Tapping to create a threaded hole for screws or bolts
Reaming to smooth out existing holes while removing much less material compared to drilling

Fabrication and Assembly

After production, fabrication and assembly take place to improve the finish of the product. Ensinger offers various fabrication services including:

Plastic Annealing is a way to reduce internal stresses in manufactured plastic parts
Component Assembly to deliver your product fully assembled by bonding parts, installing threaded inserts, or complete bearing assembly
Plastic Bending to form an exact shape to fit your application
Plastic Bonding to join polymers or other substrates together can be difficult and requires a deep understanding of polymer makeup and physical characteristics

Partner with Ensinger for Your Plastic Parts Manufacturing Needs

At Ensinger, our team has the capabilities and experience needed to take over your plastic parts manufacturing needs from start to finish. Not only can we assist with engineering and design, but we can work with your part through manufacturing and finishing services.

The Plastic Parts Machining Process: From Engineering to Assembly