Categories
Plastic Product Manufacturing

Plastic & Metal Product Manufacturing Processes

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 https://www.gidcompany.com/.

Have any queries regarding plastic product manufacturing? Just call Jim Grimes at 714-323-1052 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.

Categories
Product Design

The Importance of New Product Design – Manufacturing Cost Perspective

Introducing a new product into the market is a dream come true for every inventor. Introducing a new product, however, is not easy. While conceiving an idea and outlining it on a piece of paper might be simple, creating a new product from that idea is certainly a challenging task. New product development involves the creation of a constructive new product design, development of alpha and beta prototypes, testing of the prototypes, development of production tooling, mass-manufacturing of the new product, distribution of the new product, and many other crucial processes in between. Each new product development stage is vital, but in this blog, we will shed some light on new product design.

Like every other stage involved in new product development, the stage of new product design is very important. Because it comes in the early stages of new product development, understanding the product design stage demands a bit more attention. Besides, since it is one of the primary stages of new product development, the entire outcome depends on it; hence, more care is needed during this stage – the product design stage.

The success of any product heavily relies on its product design. Product design by definition can be said as, “a process of defining and creating constructive designs for a product, so as to ensure that the new product becomes successful in the market.” New product design addresses numerous things, however. For one, during the product design stage itself, the inventor can get a clear idea whether or not it is possible or feasible to create the new product. Another crucial thing the product design addresses to is the cost of manufacturing the conceived product. Most inventors, often overlook this “new product design and cost of manufacturing” aspect. In fact, some inventors do not even know what the effects of new product design are on the cost of manufacturing the final product.

Product design is not only defining and creating alluring designs for the new product, but it is also about crafting practical, functional, and cost-effective designs for the new product. Aspects such as, how many parts the new product will have, how compact or large the parts will be, what material(s) the parts will be made of, what process will be used in the production of those parts, and many others are also included in product design. After numerous brainstorming sessions, computer analysis results and mock-ups, a perfect new product design, or at least, a near-perfect new product design for a product is realized, which is beautiful, practical, functional, and most importantly, the one that facilitates economical mass-manufacturing.

Developing an efficient new product design is indeed an overwhelming task, and it might be impossible for inventors to develop such efficient designs on their own. Fortunately, there are professional product design companies, like the GID Development Corporation, that specifically deal with creating sensible new product designs and helping inventors develop successful new products at economical costs.

GID Development Corporation, an eminent new product design company in California, USA, has the experience, knowledge, tools and a team that help inventors with constructive product designs for their new product ideas. Utilizing cutting-edge technologies, like 3D EXPERIENCE Platform from Dassault Systèmes, which includes SOLIDWORKS, CATIA V6, and other apps, and their decades of experience, the veterans at GID Development Corporation create definitive product designs that are neat and functional as well as feasible and economical to mass-manufacture. Whether it is creating an efficient product design for electromechanical products, medical device products, products with imbedded software, products with electronics, or any other generic or special-purpose products, GID Development Corporation will “Get It Done!”

Some of the product design principles that GID Development Corporation follows include:

  1. Derive visually-appealing product design that is error-proof to assemble and easy to mass-manufacture with shortened product development cycle time
    • Determine and select cost-effective material(s) and production process
    • Attain a knowledge base of tooling requirements
    • Develop efficient production tooling
  2. Create a modular product design with minimized parts count
  3. Design parts with self-locating features
  4. Design parts with self-fastening features
  5. Emphasize “Top-Down” assemblies
  6. Design for a base part to locate other components
  7. Design for component symmetry for insertion

Adhering to all the above product design principles, and other ubiquitous as well as unique design principles, GID Development Corporation creates exceptional new product designs, which facilitate economical mass-manufacturing.

Along with new product design, GID Development Corporation also helps inventors with new product development, product prototype development, product prototype testing, product pre-tooling development, product mass-manufacturing, product branding, product distribution and many other product fulfillment services.

Learn more about new product design company in California, GID Development Corporation, by visiting https://www.gidcompany.com/.

Currently, GID Development Corporation is offering a free telephonic conference to help answer various product design and development-related questions that inventors may have. Anyone who is interested can just call Jim Grimes, one of the veterans at GID, at 714-323-1052 between 8:00 AM to 5:00 PM PST.

Categories
Custom Product Manufacturer

Choosing a Custom Product Manufacturer in the United States

Someday, early in the morning you had your eureka moment. You know that the new product idea that just evoked your mind is worth development and will generate a huge profit for you. However, you don’t have a skilled workforce, adequate experience to initiate the project nor you have industry certified tools to embark the project. So, should you drop the idea of developing a revolutionary product? Absolutely not.

In the age of globalization, there are thousands of product manufacturing companies keen to help with custom product development. Here’s how to choose the right custom product manufacturer to get the job done in the most professional and efficient manner.

What to Look for When Hiring a Custom Product Manufacturer

  1. Hire a company whose primary business is product development
  2. Hire a company having a collection of technical and experienced professionals
  3. Hire a company familiar with the latest technologies
  4. Hire a company having its root deeply penetrated in the marketplace
  5. Hire a company having a team to offer a fresh point of view
  6. Hire a company having dedicated resources to bring significant specialized experience to any project
  7. Hire a company that knows and offers the right combination of services

According to an ancient quote, “If the only tool you have is a hammer, you will see every problem as a nail”. Therefore, find a full-service provider who fits your project requirements, and not one having limited resources and limited industry experience. You should strictly follow this quote while finding a product manufacturing company because, in the 21st century, injection molders, rapid prototypers (SLA service bureaus), board houses, and even plastic suppliers describe themselves as custom product manufacturers. As a responsible entrepreneur, you need to ensure that the product development company you hire is not limited to solutions based on their core business.

Contact the GID Development Corporation

For startups, small, and medium-sized businesses who want to establish their unique presence in the market, we help them with everything they are searching for. Hiring GID as a custom product development will allow you to take advantage of opportunities, which are not part of your core business and develop products that are not simply extensions of their existing product lines. At GID, we have dedicated resources to professionally execute all of the design and engineering jobs.

The GID Development Corporation is not an ordinary manufacturer, a molding shop, or a circuit board house. If you need the services of skilled product developers, we have the resources, the tools, and the experience to bring your ideas into reality. Contact us at www.GIDCompany.com.

Categories
Product Manufacturing

Dear Entrepreneurs, Do You Know To What Extent Your Product Manufacturing Process Is Digitized

Being an established product manufacturing company in USA, at the GID Development Corporation, we know it very well that the product design, product prototyping, and product development are in a stage of major transformation across the globe. A message from the market to accelerate the development process provokes product manufacturing companies to find advanced ways to improvise their manufacturing processes and produce technological capabilities to shorten the product development lifecycle.

Digitalization of product design and product development processes has helped manufacturers in reducing the development life significantly, eventually minimizing a product’s time to market. However, countless startups and small businesses still find it difficult to implement the digital manufacturing strategy. Here in this blog, we will discuss significant transformation stages that any product manufacturing company is looking for digitization goes through. The points covered here will help you determine to what extent is your organization’s product manufacturing process is digitized. What steps should be taken to elevate the transformation process and how digitizing can benefit you in the product development process.

Use of CAD tools

The use of 2D CAD tools for product design is quite common across most product manufacturing companies. Many industries such as civil, mechanical, and electrical frequently require 2D drawings to address various purposes. Shop floor requirements are often in terms of a 2D format, which provide flawless communication within the departments inside an organization and between the clients and the organization. However, considering the other technical advancements in the industry, 2D is looked upon as an initial step towards digitizing the product manufacturing process. 2D has its own limitations and does not convey the information to an individual who is less technical.

Transformation from 2D to 3D

The real digital transformation of a product manufacturing process comes with the adoption of 3D CAD tools. Undoubtedly, 3D printing is highly advantageous and brings countless benefits that help in reducing overall manufacturing time. It offers an in-depth insight on a product design and its workings, to demonstrate the product’s characteristics in a better way.

Across the globe, there are still some companies that use traditional 2D CAD tools to avoid spending extra cost and time in manufacturing 3D models from the past 2D drawings repository. However, the real advantage comes when we use both – the 2D and 3D tools.

Virtual Testing

Because of its amazing ability to predict design behavior right before the manufacturing process, most product design and development companies across the globe prefer to use the virtual testing to test a product design. With comprehensive 3D modeling capabilities, the next digitization phase is to implement virtual testing in the design process.

Before moving on to the bulk manufacturing process, a product’s behavior and its performance can be easily determined with the use of virtual simulation tools such as, computational fluid mechanics and finite element analysis. Moreover, virtual testing also reduces the number of prototyping trails, as initial design data is tested at the start point. This eventually helps a product manufacturing company to reduce product development cycle significantly.

Rapid Prototyping

Product prototype development is an ongoing trend within the industry of new product development, allowing product development companies to physically feel and test a concept before proceeding with the manufacturing process. Due to constant advancements in the world of 3D printing technologies and materials, the product development industry is about to witness a standard shift in a way products are being developed.

Before the bulk manufacturing process, the use of rapid prototyping allows the determination of necessary development processes and equipment as well as fixes flaws in the design to eradicate last minute manufacturing errors.

Owning to the fact the digitization reduces overall manufacturing time and eventually a product’s time to market, most product manufacturing companies across the globe are busy in digitizing their product manufacturing processes for all the engineering domains. Its adopters have admitted a notable growth in their operational efficiency, enabling the production of better and cost effective products.

Are you an entrepreneur or an innovator whose product development strategy still follows a traditional approach? If so, the time is now to adopt this trend, as getting it right is essentially the required to survive in a competitive scenario. For any assistance related to product design and development, contact us at www.GIDCompany.com.

Categories
Plastic Product Manufacturing

Rotational Molding, its Advantages and why it is Best for Manufacturing New Plastic Products

Also known as Rotomolding or Rotocast, Rotational Molding is a thermoplastic process for manufacturing hollow plastic products and parts. It is an extremely specialized and unique plastic product manufacturing process in which powder or liquid resin is placed into a hollow mold and then that mold is bi-axially rotated over and over until the resin melts and coats the inner wall of the mold cavity. In the next step, the tool is cooled and the part is extracted from the mold.

What is Rotational Molding?

When it comes to plastic product manufacturing, there are many great manufacturing processes (such as injection molding) that help in the development of highly precise finished products. However, every process has its own limitations. Rotational Molding is a specialized technique that is used to create a hollow plastic product with high precision. In this process, heat is used to melt and fuse the plastic resin in a closed mold. Unlike other manufacturing processes, no pressure is involved while developing a new product.

Mainly, the Plastic Rotational Molding can be classified into four different stages, i.e. loading the resin in the mold, heating and fusing the resin, cooling and finally extracting the product from the mold. Once the powered or liquid resin is placed in the mold, the charged mold is then positioned into an oven and rotated upon a rotating two axis arm at a slow speed. As the mold containing resin is constantly heated¸ the resin adheres to the mold’s inner wall until it is completely fused. To ensure the gradual lowering of the temperature, the mold is then cooled with the help of water spray or air or a combination of both while still rotating. Once cooled, the mold is opened, the final part is extracted, and the mold is filled with the resin for the next production cycle.

With the advancement in the manufacturing technology, a wide variety of materials such as, polyethylene, plastisols, nylon, fluoropolymers, polycarbonate, polypropylene, polyurethane, and elastomers can be used to produce plastic products using rotational molding. It is one of the most economical plastic product manufacturing processes, and more importantly, products and parts can be developed in a variety of sizes and shapes that would be impossible to produce by any other process.

Why Use Plastic Rotational Molding for Manufacturing New Plastic Products?

There are plenty of manufacturing processes; however, Rotational Molding offers a unique set of rewards. Rotational molding is a plastic product manufacturing process that is widely used to develop highly durable and long-lasting plastic products and parts. This manufacturing process offers the freedom to use the raw material of your choice; however, polyethylene is the most commonly used material. Ease of use is another advantage of this process. This process requires a mold, which can be built using different methods such as, casting, machining or fabricating a mold.

Advantages of Rotational Molding

Rotational Molding is a unique manufacturing process. It is a plastic product manufacturing method, in which the heating, melting, shaping, and cooling all occur after the resin is placed in the mold; hence, it can be easily controlled. Rotational Molding can be used to produce small to large, simple to complex parts in a very less time.

  1. It is an affordable manufacturing process
  2. It requires low initial tooling costs
  3. It can help you manufacture large products and parts economically
  4. It can help you develop durable, long-lasting products and parts
  5. It can help you develop plastic products or parts within the deadlines
  6. It offers design flexibility
  7. It ensures stress-free manufacturing of plastic products or parts
  8. It facilitates easy prototyping
  9. It allows raw material of your choice

The GID Development Corporation is an American Plastic Product Manufacturing Company that employs rotational molding and injection molding with specialized experience in manufacturing large, complex plastic products. The Rotational Molding experts at the GID Company can help you determine if the rotational molding process is right to produce your part or project.

Categories
Plastic Product Manufacturing

How will you find a Top Notch Product Manufacturing Company in the USA?

Congratulations for having a million-dollar product idea. Your parents, friends, colleagues, neighbors and everyone else believe your product is going to change the world. However, you know the fact that just having a revolutionary product idea is not going to change the world unless it is transformed into a fully functional product. A real world question arises – How you will bring your idea to store shelves?

Many entrepreneurs and inventors lose hope and panic under these circumstances, and drop the plan of transforming their idea into a state-of-the-art product. However, all these heartbreaking problems can be solved with the help of an experienced product manufacturing company. Finding and hiring a custom product manufacturer is a challenging task, especially when dealing with companies overseas. Here are some tips to find the perfect product development company, and they are as follows:

Ask for recommendations – Ask your friends, colleagues, and everyone whom you know to refer a new product manufacturing company. Ensure your contacts have a fruitful relationship with the company to lend extra credibility to their recommendations.

What is the reputation of the company – Do not get enchanted immediately after seeing a company’s online profile and a huge warehouse, instead have a little patience. Visit the company and ask them to see a list of clients they have worked for in the past. If possible, contact the clients and ask about their experience. For in-depth understanding of a company’s manufacturing potential, you can also ask their clients to send you some samples of their work to see how it appears in person.

Make maximum use of the online platform – Use online platform to gain insight, compare price, and ask questions. Although, the internet is the best medium to collect useful information, there are chances of fraud and misinformation. So, prior to engaging with a company or hire their manufacturing services, it is recommended to double check the company’s existence and its reputation. Ask them a few questions related to your manufacturing requirements, and if they offer speedy responses, the company is good to hire.

Request a prototype – If you live in the United States, then it is recommended to prototype your concept in the U.S. before hiring any offshore product manufacturing company. Product prototype development may be a costlier affair in the USA, but it will help you save a lot of time and money in the end. At the completion of this step, you will have more control over your product. However, before prototyping, read these 5 important tips for successful product prototype development.

Manufacturing a fully functional product from scratch is a complicated task that requires a skilled workforce, latest manufacturing tools, and a zeal to overcome all the manufacturing challenges. It is a complicated task full of heartache, excitement, and headaches, but in the end, seeing your concept come to life is always going to be worth the effort.

The GID Development Corporation is a product design and development company based in America. If you require any sort of help, advice or prototyping assistance, then call GID at 714-323-1052 to talk to our prototyping experts. For a free analysis of your new product idea, contact us at https://www.gidcompany.com/contact-us.