Creative Engineering

Performance Enhancement to Custom Part Creation – Consider Going to Plastic in 5 Steps!

From design to prototyping to process engineering, our experience with the wide range of plastic solutions allows us to solve any plastic component challenge.

Bring DPI your cost reduction project, problem part, weight reduction or custom part creation and we will help you find a plastic-based solution.

We are creative, engineering-minded problem solvers. And it shows.

Our years of experience and expertise, combined with the advancing plastic industry, allows us the opportunity to create tailored, useful plastic part solutions for our customers.

Our equipment is fitted to run cost-effectively for both high-volume or low-volume product production so we can make unique, custom pieces quickly within your budget. Our plastic production process is also capable of handling medium volume parts (500-1000 parts).

Our testing capabilities ensure that products meet or exceed the specifications required by the application, and our streamlined approach reduces material waste and processing hours.

We also work closely with the leading chain manufacturers in the industry. We visit job sites across the country to review installation methods and to assess our customers’ needs. We host end-users at our facility to detail our unique processes and our proven results.

Let’s take a look at your part to determine its manufacturability. We first need to profile the component.

What is it used for?
What material is used today?
What are the tolerances and loads?
What is the speed that this part is moving?
What are the environmental factors for this part – oils, temperatures, presence of dirt?
What are the annual quantities needed and cost tolerance?

As the profile of the part is developed, the plastic type and processes will start to be clear. When it is determined that a component can be made with a plastic process, the true steps begin for manufacturing as explained here.

The 5 Steps to Manufacturability

Manufacturability is the ability to manufacture a part utilizing the most efficient method and cost-effective materials, ultimately resulting in a consistent and identical end product. With different and distinct manufacturing processes available, it is vital to understand the following steps that determine the manufacturability of your desired product. These stages will help determine the best practice for manufacturing any part using plastic.

  1. Prototyping
  2. Design
  3. Materials
  4. Manufacturing Process
  5. Quality Assurance

At DPI, we know how to bring your part to life. We create hundreds of new parts every year. Customers initially come to us for a one-time solution, and after realizing our extensive experience and broad capability they usually return for other plastic applications. We have the ability to conceptualize a part that you’ve drawn on the back of a napkin! We will take that drawing and use the right tool and design for success. The first stage in determining the manufacturability of a product begins with prototyping. It is a low-cost concept used to validate the product idea and prove feasibility. The prototype is built in the form of an engineered drawing, a 3-D model, or a 3-D print to test a concept, process, or material.

Working with customers, our engineers determine the function of the desired product and consider the aesthetic properties. Using an accelerated fabrication method, we are able to produce an initial product that can be analyzed and critiqued by the customer. Gaining feedback is vital as the part can be adjusted geometrically for optimal material yield, cycle times and tolerances, and manufacturing feasibility. Our production experience enables us to suggest design modifications because we know the production process. We see where there are undercuts and potential manufacturing issues and will resolve them before they become an issue.

Material selection is crucial for the product’s desired use. Diversified Plastics’ team members are material experts and consider design life, complexity, frequency, and wearability when recommending the best-suited raw materials. We will also incorporate custom resins, additive packages, and custom color matches so the final product provides the desired solution and achieves maximum results.

There are thousands of types of plastics with hundreds of applications, and our experience allows DPI to find the best solution for the part. When the application has a unique tensile strength, unusual need for flex or nonstandard chemical compatibility needs, DPI will find the answer. If DPI does not already know the best plastic to start with, their extensive network of reliable suppliers will help to define the best plastic for the job. (To read more about “Why Plastic?” review this article)

Depending on the specific part and quantity needed, many different manufacturing processes can be implemented. Utilizing the Diversified Plastics MultiFabTM technique, we are able to analyze and modify manufacturing processes to optimize customer cost-savings as well as reduce waste and improve efficiency.

Machine it or Mold It? Read more here.

Producing a quality, uniform product without mistakes or defects is the ultimate goal of manufacturability. Diversified Plastics employs specific and strategic measures to ensure our manufactured products meet superior standards: 

  • Continually testing of our apparatuses and fixtures
  • First and last article check for each operation
  • Customized and individualized customer Quality Assurance Plans 
  • ISO Compliant

One of the keys to working with Diversified is that we are large enough to know how to accomplish any manufacturing challenge and small enough to adapt to the customer process needed. 

The Diversified Commitment

The Diversified Plastics team prides itself on being more than a manufacturer. We are creative, engineering-minded problem solvers that are continually looking for ways to improve the life of a product as well as reduce procurement and maintenance costs for our customers. For over 43 years, Diversified Plastics has been consistent in designing custom engineered plastic parts that are manufacturable.

Our knowledge will quickly get your project on the right path. Call us today!