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Plastic & Metal Product Manufacturing Processes

Plastic Product Manufacturing
Plastic & Metal Product Manufacturing Processes 5.00/5 (100.00%) 1 vote

One important aspect that every industrial designer and mechanical engineer should consider is the selection of the right product manufacturing process. For product development, there are many manufacturing processes that engineers can utilize; however, choosing the right one can greatly affect the cost of manufacturing as well as the success of the final product. Here is a brief on some of the most common plastic product manufacturing and metal product manufacturing processes.

Plastic Product Manufacturing Processes

For the sake of this discussion, let us assume that you need to make at least 10,000 parts. For less quantity, rapid prototyping or 3D printing processes are more appropriate and economical.

Here are some plastic manufacturing processes that plastic product manufacturers commonly utilize to mass produce plastic parts and components.

  1. Injection Molding: Plastic injection molding is the most preferred process that produces parts and components with the lowest cost per part. The process is ideal for moderately-sized production runs. The production tooling cost is a bit of concern, especially if you do not have a definitive mold for the plastic part. Nevertheless, you can use aluminum molds until you get the definitive mold design. Once you have the definitive mold design, you can shift to stainless steel molds, which are durable and suitable for a high-volume production.
  2. CNC Machining: Computer numerical control machining or just CNC machining is the process in which computers play a big role in controlling the CNC machines like mills, plasma cutters, drills, etc. CNC machining is an ideal process to employ for small-sized production runs for small parts. The process allows precision and good surface finish too. The drawback of CNC machining is the high costs. Nevertheless, CNC machining offers automation, which eliminates manual labor and errors caused by manual laborers.
  3. Rotational Molding: Rotational molding is an appropriate plastic product manufacturing process to produce soft, rubbery parts. Both simple and complex parts can be produced using rotational molding. It also helps produce several pieces of a single part, which can then be assembled together. This eliminates overall fabrication costs. Rotational molding also eliminates significant wastage of material. The drawback of this process is it does not facilitate precision. And just like plastic injection molding, the production tooling cost is a concern.
  4. Thermoforming: Thermoforming is a suitable process to manufacture large plastic parts. The production tooling cost is lower than other plastic product manufacturing processes. The production time is also lower. The disadvantage of thermoforming is that it does not offer precision. Intricate shapes and good surface finish are also hard to achieve with thermoforming.

Metal Product Manufacturing Processes

Metal product manufacturing is more expensive than plastic product manufacturing because metals are more costly than plastic materials. It is possible to rapid prototype or 3D print some metal parts, but it will prove uneconomical.

Here are some metal manufacturing processes that product manufacturers commonly utilize to mass produce metal parts and components.

  1. CNC Machining: Aside from the plastic parts, with CNC machining, it is possible to produce metal parts. Thanks to computers, playing a role in controlling CNC machines, the process is appropriate for making complex parts. Precision is easy to achieve with CNC machining. The drawback of CNC machining is the high costs, even for producing small parts.
  2. Die Casting: Die casting is a suitable metal product manufacturing process to produce metal parts with high dimensional accuracy and smooth surface finish. The process facilitates rapid production rates. The per part cost is also lower than other metal manufacturing processes. The drawback, however, is the high production tooling cost – perhaps it has the highest tooling cost.
  3. Investment Casting: One of the oldest processes, investment casting is appropriate to manufacture complex parts with a very smooth surface. The process also offers exceptional dimensional accuracy. The drawback, aside from the cost, is the long production-cycle times. For high-volume manufacturing, the process could prove to be expensive and infeasible.
  4. Sand Casting: Sand casting is one of the most popular processes to produce small and complex metal parts. Instead of metal molds, this process utilizes sand molds. This substantially reduces the cost. With sand casting, it is possible to achieve high dimensional accuracy. The process is suitable for low to medium production runs, but for high volumes, it will prove to be infeasible.

Aside from these processes, there are many other plastic product manufacturing processes and metal product manufacturing processes. Choosing the right one will affect the cost of manufacturing and the success of the final product.

Looking for a good plastic product manufacturer in California? Look no further than GID Development Corporation. A product development company, based in California, GID Development Corporation provides exceptional product design, product prototyping, plastic product manufacturing, 3D printing and other services. With their experience and expertise in injection molding, CNC machining and other processes, the professional industrial and mechanical engineers at GID Development Corporation can help you develop exceptional new products.

Whether it is a complex electromechanical product or a simple medical device product, GID Development Corporation can “GET IT DONE!” To learn more, get in touch at http://www.gidcompany.com/.

Have any queries regarding plastic product manufacturing? Just call Patrick at 714.528.2482 between 8:00 AM to 5:00 PM PST, for a FREE 15-minute telephonic conference. He will answer to various questions regarding plastic product manufacturing and rapid prototyping.

Rapid Product Designing & Rapid Prototyping – Advantages

3D Printing
Rapid Product Designing & Rapid Prototyping – Advantages 5.00/5 (100.00%) 1 vote

New product design and product development, both have come a long way today. Traditionally, product designs were hand drawn. Now, product designers are creating detailed, clear product designs using special-purpose computer applications, like Dassault Systèmes’ 3D EXPERIENCE 2016, SOLIDWORKS, and 3DVIA among many others.

For product development, specifically the product prototype development, engineers nowadays are utilizing revolutionary additive manufacturing (popularly known as 3D printing) processes, which include selective laser melting, fused filament fabrication, direct metal laser sintering, and stereolithography to name a few.

These modern rapid product designing and rapid product prototyping techniques are geared toward the swift, precise, and effortless development of new products. More importantly, with these state-of-the-art techniques, it is possible to minimize the cost of new product development! Let us look at some of the advantages that these computer-assisted 3D product designing and 3D printing techniques offer.

  1. These contemporary techniques radically minimize the time of turning a product concept into reality. Simple product concepts can be brought to life in a matter of days, and complex product concepts in a matter of a few months. Therefore, inventors can quickly realize their dreams of swiftly getting groundbreaking products into the market and selling them to make profits.
  2. These techniques help save money. Creating product designs using computer applications means getting definitive designs with a minimum number of attempts; hence, it avoids redundant costs of creating multiple product designs. 3D printing, on the other hand, eliminates the need for plastic product manufacturing tools or other molding tools needed for building product prototypes. This elimination of tools substantially saves money for the inventors.
  3. The modern techniques help mitigate product redesigning risks. Since the product designs are created virtually on the computer, they are, in most instances, ideal in every manner. Even if they are not, or if any changes are required, the product designers can quickly and effortlessly modify or change the product designs. These new product designs are then efficiently and economically 3D printed, saving time, money, and more importantly, the efforts of doing everything from scratch for the inventors.
  4. The techniques facilitate in the creation of the definitive product. Because 3D product designing is carried out virtually, using special computer applications, the chances of leaving out any product construction requirements are almost next to nothing. In the virtual world, the product designers and product developers can test almost every aspect of the conceived product. This way, they can add, remove, and experiment with the various features of the imagined product without actually creating any mockup or prototype!
  5. These techniques allow quick creation of product prototypes. Once the product designs are ready, they will be fed to a 3D printer (it’s a kind of an industrial robot). The 3D printer is then configured according to the required specifications. Once the 3D printer is configured, it will then extrude material into the desired shapes. The entire process, from feeding the product design into the 3D printer to the extrusion of the material into the desired shapes, is substantially swifter than injection molding techniques.
  6. These breakthrough techniques enable the creation of custom shapes. The 3D printer extrudes the material into desired shapes or geometries based on the instructions received from a computer. In simpler words, a 3D printer prints a material, instead of ink, based on the design it is provided. Ergo, it is possible to create custom, intriguing shapes effortlessly. This advantage of these techniques is very beneficial when it comes to medical device product development as well as electromechanical product development.
  7. These techniques make it possible to develop product prototypes using any material. Not only polymer and its variants, but 3D printers are capable of accepting and printing materials like rubber, ceramic, edible materials, and almost any metal alloy!

These were just some of the many advantages that rapid product designing and rapid product prototyping techniques offer. They are just ideal for new product design and new product development, especially product prototype development.

If you are an inventor and want to realize your product idea with these revolutionary product design and product development techniques, then partner with GID Development Corporation. A leading product design company in California, USA, GID Development Corporation provides rapid product design, rapid prototyping, rapid product development and other new product fulfillment services. They even have the ability to develop CNC-machined prototypes using different plastics and metals. This ability of GID Development Corporation comes in very handy, especially when the raw materials for rapid prototyping processes are not suitable or durable enough for the conceived product.

Whether you have a revolutionary idea for a medical device product, sports product, electromechanical product, a product with embedded software, a product with electronics, or any unique product, the product development company in California, GID Development Corporation will absolutely “GET IT DONE!”

Learn more about GID Development Corporation: http://www.gidcompany.com/

Have any queries regarding rapid product prototyping or 3D printing? Just call Patrick at 714.528.2482 between 8:00 AM to 5:00 PM PST, for a FREE 15-minute telephonic conference. He will answer to various questions regarding product design, product prototyping, and product development.

The Costs Involved in Taking a New Product to the Market

New Product Development Cost
The Costs Involved in Taking a New Product to the Market 5.00/5 (100.00%) 1 vote

When it comes to realizing a new product idea into the physical form, many entrepreneur inventors underestimate various costs that are involved. These inventors underrate not only the product development costs but most of the other vital costs as well.

Underestimating the costs is especially true for medical device products. Inventors should never make the mistake of misjudging various costs, as it can hinder their success. Rather, they should learn and know all the different types of costs involved in bringing a new medical device product into the market.

Remember, the total cost to take a new product from just a mere concept to a mass-manufactured product widely varies. If it is a complex product, the total costs may reach to a hefty figure. Anyway, let us look at some of the most common costs that are involved when it comes to realizing a new medical device product into a physical form and taking it to the market.

Product Design Costs

The conceived product idea needs to be elaborated, and product design helps in this regard. Rough, hand-drawn sketches are carefully drawn into proper drawings by the professionals. These drawings are then elucidated even more using computer applications, like CATIA, SOLIDWORKS, etc.

While creating the drawings or 3D models using a computer application, many changes are also made and tested in order to achieve a definitive and feasible product design. Making professional drawings and computer-generated 3D models requires experience and skills, and it costs a reasonable amount of money. The computer application itself, by the way, will cost a substantial amount of money.

Product Prototyping Costs

Every new product idea needs a prototype. Based on the definitive product design, a product prototype can be made. A product prototype gives the clear understanding of how the conceived product will physically look, feel and function. At the same time, a product prototype helps test the conceived product, eliminate any defects, and enhance certain functions.

Product prototype development is a complex task as it involves creating near perfect examples of the final product. It is arduous and intellectually challenging job. It will cost a substantial amount to develop definitive product prototypes.

Product Development Costs

Based on the product prototype, the final product is developed. Since it is a medical device product, the product development costs can be broken down into (normally) three groups: the mechanical, the electronic, and the plastic.

While the mechanical and electronic do all the magic, the plastic is responsible for holding the product together. Sometimes, instead of plastic, other materials may be used, but plastic is the most common, versatile, and economical material of choice.

Normally, the mechanical and electronic will be the most difficult and expensive to develop, and they will share a big proportion of the product development costs. The plastic parts or components will, comparatively, cost less to develop.

Copyright, Licensing & Certification Costs

While the normal copyright and licensing costs may not be exorbitant, the fees that inventors have to pay, if they hire professionals, are something worth considering.

For novice inventors, the process of acquiring the copyright and other licenses may seem overwhelming. At the same time, in order to protect the invention, acquiring the copyright and licenses is essential. For that reason, inventors may need to hire professionals who would help obtain the necessary copyright and licenses. These professionals will charge fees that are worth considering.

For medical device products, inventors need to obtain certain certifications from the US Food and Drug Administration (FDA). Acquiring these certifications will also cost some money.

Production Setup Costs

Inventors need to set up production facilities in order to mass manufacture the conceived product. Establishing a production facility is no easy feat, and it requires a considerable amount of capital.

Since it is a medical device product, hybrid production facility, which can mass manufacture and assemble mechanical, electronic, and plastic components, needs to be set up. Further, because it is a medical device product, the facility also needs to have a sterile environment. Forming such a facility will cost a massive amount of money.

The inventors, of course, have the option to partner with existing manufacturers, but that will also cost – not as much as establishing own facility, but a significant, nevertheless.

Well, these are just some of the common costs involved in materializing a new medical device product into a physical form and taking it to the market. Other costs such as branding, packaging, logistics, marketing, and so on are also involved.

If you are an inventor and need help in realizing a new medical device product and taking it to the market, then GID Development Corporation can help. A product development company in California, GID Development Corporation specializes in new product design, product prototyping, product development, plastic product manufacturing, and other product fulfillment services.

Whether it is medical device product development, electromechanical product development, sports product development, generic or special-purpose product development, GID Development Corporation will surely “GET IT DONE!”

Want to learn more about the professional product development company in California, GID Development Company? Just visit http://www.gidcompany.com/.

A FREE 15-minute telephonic consultation is available! Just call Patrick at 714.528.2482 between 8:00 AM to 5:00 PM PST.

How to Take Your New Product with Electronics to the Market?

Product with Electronics
How to Take Your New Product with Electronics to the Market? 5.00/5 (100.00%) 1 vote

So you have a novel idea for a new product with electronics? How would you realize your product idea and take it to the market? Well, develop a product prototype, get it bulk-manufactured, and start selling! It sounds very simple, isn’t it?

The reality: nothing is simple or easy about introducing a new product into the market. And, it is even more challenging and arduous when it comes to introducing a complex product, like a new product with electronics, to the market.

Most budding innovators have the false impression that they can take a new product from concept to consumers in a short time, like within a year. That is not true for most products – even untrue for simple products.

Taking a new product with electronics to the market is expensive. Most innovators and startups do not have enough money or risk tolerance to create a definitive product in one step. If they, however, take several small steps, they can get success with their new product. Here is what an innovator or startup should do in order to realize their product and take it to the market.

Validate the Product Concept

In order to prove your product concept, the best thing you can do is create a product prototype. You will need to have a functional prototype of your conceived product. While developing a prototype, ensure to keep the cost of development as low as possible. Since your conceived idea is for a product with electronics, you will need to use breadboards as well as certain electronic modules.

A breadboard helps create an electronic prototype without the need of a specific or definitive PCB (printed circuit board). A breadboard is generic and reusable, so you can create any circuit on it again and again. It is an excellent board for creating and experimenting electronic prototypes.

To create a prototype for a product with electronics, you can also use Arduino. Arduino is a popular electronic development kit, which helps create advanced prototypes for products with electronics. Arduino is a microcontroller-based kit, and the best thing about it is, it is very inexpensive.

Electronic modules are those components that are designed to perform specific functions. For instance, electronic modules may be used to execute functions like video capture, GPS, Bluetooth, and Wi-Fi among many others.

While a product prototype is not something that you can sell into the market, it is certainly the “Thing” that helps you prove, your conceived product idea actually works.

Validate that the Product Will Sell

In order to prove that your conceived product can actually be sold in the market, you will need to create a definitive prototype – a close substitute for the final product. This close substitute or definitive prototype needs to be produced in a small quantity so that they can be sent to the market for testing and getting valuable feedback.

Innovators will never know what the customers precisely want. They can assume, but will not know what the potential users actually want. The best way to know what the customers want, however, is with their feedback!

So to create a close substitute or definitive prototype for your product with electronics, you will need to look farther than electronic development kits (breadboards and Arduino). What you will need is actual printed circuit boards, specifically designed for your conceived product. On this PCB, you will need to integrate actual electronic components. This prototype should perform all the functions that are expected in the final product.

Unlike initial prototypes, creating definitive prototypes is challenging. Therefore, partnering with a product prototype development company that has experience with the development of products with electronics is a good idea. Such a product prototype development company has the knowledge in the field of electronics, and will help create definitive product prototypes that can be put on the market for testing and getting feedback.

Now the Profit

In order to make the profit, you need to create a perfect final product or an archetype, bulk manufacture it, and send the bulk-manufactured product to the market to the actual customers. An archetype of a conceived product is created after eliminating defects and improving certain functions based on feedback received on the definitive prototype.

Once the archetype is ready, the next step is to partner with a manufacturer. Since it is a product with electronics, it will need a plastic casing. Therefore, you need to partner with a unique plastic product manufacturer who not only specializes in plastic product manufacturing but also in handling electronics. If the unique plastic product manufacturer has the experience in helping take the bulk-manufactured products with electronics to the market, then it is an added advantage. Else, you will need to find professionals who can help bring your new product to the market.

If you have a unique idea for a new product with electronics and want to realize the product and bring it to the market, then professional help is available! GID Development Corporation, an eminent product design company in California, helps innovators in designing, prototyping, and developing a wide range of products, including products with electronics, electromechanical products, products with imbedded software, sports products, medical device products, and more. Aside from product design, product prototype development, and new product development, GID Development Corporation also specializes in plastic product manufacturing. With its plastic product manufacturing specialization, GID Development Corporation can help bulk manufacture a wide range of products. The professionals at GID Development Corporation also assist innovators to take their new products to the market.

To learn more about GID Development Corporation, a leading product design company in California, visit http://www.gidcompany.com/.

You can now have a free 15-minute telephonic conference with one of the professionals at GID Development Corporation. Just call Patrick at 714.528.2482 between 8:00 AM to 5:00 PM PST.

Getting a Product Prototype Developed

Getting a Product Prototype Developed
Getting a Product Prototype Developed 5.00/5 (100.00%) 1 vote

Product prototype development is one very important step. No entrepreneur inventors can successfully bring a new product to the market without having a prototype developed for it first. A product prototype is the first physical form of a conceived product idea. It gives a better perception, whether the product would work or not. A product prototype also helps identify any problems that the product may have; knowing what the potential problems are beforehand will help eliminate those problems and make the final product better.

For entrepreneur inventors, product prototype development can be radically tough. Fortunately for them, they do not have to make prototypes themselves, as there are many product prototype development companies, engineering firms, machine shops, and other specialized places that can create product prototypes swiftly. Here are some steps that entrepreneur inventors should consider when it comes to product prototype development:

Step 1. Create conceptual sketches of the imagined product, and then create exhaustive drawings for the same. To create conceptual sketches, inventors can try the traditional approach – use a pencil / pen and papers. They can also hire someone to draw the sketches. Rough sketches of the conceived product are necessary. Based on these rough sketches, inventors should get the detailed drawings of the product drawn on the computer. CAD (computer-aided design) applications can help in this regard. These detailed drawings are what inventors need in order to explain their product concept to the prototype development company.

Step 2. Search and team up with a good product prototype development company that can help create reliable prototypes based on the requirements and detailed drawings. If the conceived product is to be made from plastic, partner with a product prototype company that specializes in plastic product manufacturing. If it is to be made from metal, seek a company that specializes in creating metal prototypes. If the conceived product is to be made from thermoplastic, rubber, ceramic or other such malleable materials, then approach a prototype development company that specializes in rapid prototyping or 3D printing (additive manufacturing). Rapid prototyping and 3D printing, by the way, are modern processes that facilitate swift product prototype development.

Note: Get the prototype developed of the same material you intend the final product to be made of; that way, you can get the proper understanding and feel of the conceived product.

Step 3. Redevelop the prototype, until it becomes the archetype of the conceived product. No one can have the perfect prototype on the first try. Several prototypes need to be developed in order to get the archetype, based on which mass production can be initiated. There are certain technologies available, like DS 3DEXPERIENCE Platform, which includes SOLIDWORKS, SIMULIA, GEOVIA, CATIA V6, etc., that help create swift and accurate prototypes; yet, at least, few prototypes need to be made. Often, the redevelopment of prototypes arises due to functional or structural changes; however, other factors may also incite the redevelopment of the prototype.

Step 4. Initiate the mass manufacturing based on the archetype or final product prototype. Now that the archetype or the final product prototype is ready, which is perfect in every sense, entrepreneur inventors should proceed with mass production of the conceived product. Partner with a reliable product manufacturer or, if the budget is not the constraint, set up your own manufacturing facility. Once the product starts rolling out in bulk quantity, take it to the market and start selling to the potential customers.

If you need help with product prototype development, then get in touch with GID Development Corporation. A leading product prototype development company in California, GID Development Corporation not only provides prototype development service, but product design, product development, and other product fulfillment services as well. Just head over to http://www.gidcompany.com/ to learn more.

GID Development Corporation always believes in assisting their customers in any way they can; hence, they are currently offering a 15-minute free telephonic conference to answer various product design, product prototyping and product development-related questions that the entrepreneur inventors may have. All the entrepreneur inventor needs to do is call Patrick at 714.528.2482 between 8:00 AM to 5:00 PM PST.