Definitions vary and may differ at different organizations, but the definitions below may be used as a starting point.
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Concept Model: a physical model made to demonstrate an idea. Concept models allow people from different functional areas to see the idea, stimulate thought and discussion, and drive acceptance or rejection.
Prototyping Attributes
Speed: turnaround time to convert a computer file into a physical prototype
Appearance: any visual attribute: color, texture, size, shape, etc.
Assembly/Fit Testing: making some or all of the parts of an assembly, putting them together, and seeing if they fit properly. At the gross level, this checks for design errors, such as placing two tabs at 2 in. spacing and the mating slots at 1 in. spacing. At the fine level, this is a matter of minor dimensional differences and tolerances. Obviously, any test involving tolerances needs to use the actual manufacturing process or one which has similar tolerances.
Prototyping Attributes
Form: the shape of the part: features and size
Fit: how the part mates with other parts
Functional Testing: seeing how a part or assembly will function when subjected to stresses representing what it will see in its actual application.
Prototyping Attributes
Chemical Resistance: resistance to chemicals including acids, bases, hydrocarbons, fuels, etc.
Mechanical Properties: strength of the part measured by tensile strength, compressive strength, flexural strength, impact strength, tear resistance, etc.
Electrical Properties: interaction of electrical fields and the part. This may include dielectric constant, dielectric strength, dissipation factor, surface and volume resistance, static decay, etc.
Thermal Properties: changes in mechanical properties that occur with changes in temperature. These may include thermal expansion coefficient, heat deflection temperature, vicat softening point, etc.
Optical Properties: ability to transmit light. May include refractive index, transmittance, and haze.
Life Testing: testing properties that may change with time and that are important for a product to remain functional throughout its expected life. Life testing often involves subjecting the product to extreme conditions (e.g., temperature, humidity, voltage, UV, etc.) to estimate in a shorter period of time, how the product will react over its expected life.
Prototyping Attributes
Mechanical Properties (fatigue strength): ability to withstand large numbers of load cycles at various stress levels.
Aging Properties (UV, creep): ability to withstand exposure to ultraviolet light with an acceptable amount of degradation; ability to withstand extended applications of forces to the part with acceptable levels of permanent deflection.
Regulatory Testing: testing specified by a regulatory or standards organization or agency to assure parts are suitable for a particular use such as medical, food service or consumer application. Examples include Underwriters Laboratory (UL), the Canadian Standards Association (CSA), the U.S. Food and Drug Agency (FDA), the U.S. Federal Communications Commission (FCC), the International Standard Organization (ISO) and the European Commission (EC).
Prototyping Attributes
Flammability Properties: the resistance of a resin or part to ignition in the presence of a flame.
EMI/RFI Properties: the ability of a resin, part or assembly to shield or block Electromagnetic Interference or Radio Frequency Interference.
Food Rating: approval of a resin or part to be used in applications where it will come in contact with food while it is being prepared, served or consumed.
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Biocompatibility: the ability of the resin or part to be in contact with human or animal bodies, outside or inside the body, without causing undue adverse effects (e.g., irritations, blood interactions, toxicity, etc). Biocompatibility is important for surgical instruments and many medical devices.
Prototype models help design teams make more informed decisions by obtaining invaluable data from the performance of, and the reaction to, those prototypes. The more data that is gathered at this stage of the product development cycle, the better the chances of preventing potential product or manufacturing issues down the road. If a well thought out prototyping strategy is followed, there is a far greater chance that the product will be introduced to the market on time, be accepted, perform reliably, and be profitable.
What is the best way to get a prototype made? The answer depends on where you are in your process and what you are trying to accomplish. Early in the design process, when the ideas are flowing freely, concept models are helpful. As the design progresses, a prototype that has the size, finish, color, shape, strength, durability, and material characteristics of the intended final product becomes increasingly important. Therefore, using the right prototyping process is critical. In order to most effectively validate your design, pay close attention to these three key elements of your design: functionality, manufacturability, and viability.'
If your prototype can faithfully represent the attributes of the end-product, it is by definition functional.'These requirements often include such things as material properties (e.g., flame resistance), dimensional accuracy for fit-up with mating parts, and cosmetic surface finishes for appearance.
If your prototype design can be repeatedly and economically produced in a manner that supports the requirements of the end product, it is by definition manufacturable.'These requirements include the ability to maintain the functionality of the design as described above, keep the piece-part cost below the required level, and support the production schedule. No matter how great a design is, it will go nowhere if it can't be manufactured. Make sure your prototyping process takes this into consideration.
Finally, even if your prototype design is functional and manufacturable, it doesn't mean anyone will want to use it.'Prototypes are the only true way to verify the viability of the design in this sense.'If your design can also pass the challenges associated with market trials (e.g., trade show displays, usability testing) and regulatory testing (e.g., FDA testing of medical devices), you're well on your way to a successful product launch.
At Condale Plastics, we have a wealth of experience in the plastics industry, having created bespoke plastic extrusion products for our customers since . As our products are custom made to order, we guide our clients through the buying process, helping them to choose the right extrusion for their needs.
A big part of the job for our expert team is helping our customers choose the right plastic extrusion products for the job, and as such, we've put together this helpful guide on choosing the best extrusion for your project.
It is important to select the proper material for your product in order to guarantee its functionality and also to maximise its profitability. It is vital that you consider all aspects of how your product will be used, the environment in which it will work and the other components or articles that it will come into contact with.
There are many factors to take into account when determining the most appropriate plastic extrusion products for your usage and these should include some, if not all, of the following:-
It is important to understand the loads that will be applied to your product and the speed at which they will be applied. Will the product be compressed or stretched? Will it be subject to sudden impacts and if so what is their scale? Other items to be considered are how hard it needs to be, friction and fatigue resistance
The environment in which your product will operate will also be an important consideration in your choice of material. Is chemical resistance important? Will the product be subject to high levels of UV rays? Is water permeability a factor or is the product required to meet a specified electrical resistivity or insulation standard? These are all things that need to be taken in to consideration
The temperature that a product will be subject to may dramatically influence the choice of polymer or the additives that may be incorporated within it. What average temperatures will apply and for how long and how regularly will the extremes be reached? Heat distortion temperatures or thermal conductivity may be important factors affecting product performance. In some cases, in applications where safety is a factor, fire resistance and a material's ability to generate smoke may be key factors in their selection.
Extrusions that are to be used in the medical environment or in contact with food for example will be subject to specific legislative requirements. Recyclability or the conditions for disposal may also be critical features in your choice of material.
Colour, finish, clarity and opacity may all be critical to the functionality or appeal of your products. Select materials that will be compatible with the appearance of your final product. You may require specific colours to match a brand image or consumer legislation, your choice of material will have a significant influence on their achievement.
In some cases, where two distinct colours are required or where a rigid product needs a flexible seal or hinge, a co-extrusion of two materials may be the most appropriate solution. Material selection becomes very important as the adhesive properties and compatibility of different materials vary significantly.
The costs of different plastics are markedly different. There are many commercially available polymers that will be both competitive and meet the requirements of most applications for extrusions. If very specific thermal, electrical or mechanical properties are needed then a number of engineering materials are available, although these are more expensive. In some cases, very specific plastic materials are available that have been designed to meet the requirements of a particular application, such as aerospace. Choose the material that meets your specific requirements and that is most readily available commercially.
You may wish to consult our handy guide on materials plastic extrusion material. If your experience with materials is more advanced you may also wish to take advantage of our rapid prototyping facility. We can quickly produce models of your intended profile that help you check the form and function of your design via 3D Printed Rapid Prototyping.
If you're still unsure about which plastic extrusion product is right for your project, fear not! At Condale Plastics, guiding customers through the entire design and manufacturing process and creating bespoke solutions is all part of the job. With the latest facilities on our site, and a team of experts on hand to advise, we are able to assist with deadlines, designs and material queries, making sure you get the right extrusion for your needs.
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