A proper, detailed drawing of your product is a necessary and time-saving stage for each project. From these drawings, our CAD engineers develop 3D models and the computer programs written to produce prototypes, molds and/or mill the final product. More importantly perhaps, drawings detail the specifications and tolerances which are necessary for us ensure the quality of your product throughout the process.
For first-run products and any number of other reasons, a 3D computer model may not be sufficient and the customer may choose to first produce a prototype of their product. Although many of the processes remain the same, vacuum-forming molds can be produced from a number of inexpensive and temporary materials at a much lower cost.
The mold making process, relatively speaking, is an expensive stage of the project; especially for smaller orders. We construct positive and negative vacuum forming molds, with or without internal cooling, from a number of materials ranging from steel or aluminum to wood and plaster. Choosing the proper mold construction and material to match your product is crucial to keeping costs low.
The thermoplastic in most products accounts for between 30% to 50% of the final product cost. Determining the type, size, thickness, purity and manufacturer of the material is very important. We help you choose the proper material at the best price and arrange for material forecasting, scheduling, procurement, quality control and warehousing.
The vacuum forming process is fairly straightforward but streamlining that process to produce a consistent quality with optimal time settings is a learned skill. Our thermoformers draw on years of experience and data to achieve the optimum process for your product.
Many of the products that we produce require the removal of the thermoformed trim or a contour milled to specific dimensions. We employ a number of 3,4 and 5 axis computer operated CNC milling machines for the purpose of shaping your product to within 1/10th of a millimeter precision on a consistent basis. We also operate a CNC lathe for production of any inserts or domes which may be a part of the final product.
Plastic Systems offers a full range of in-house services to complete the project from beginning to end. Your product may require any one of a number of additional processes such as gluing, painting, printing and/or assembly. We can also procure special packaging and arrange for direct distribution to your customers if necessary.
We've listed quality control in the last position and it is indeed the final stage of any process for all products. The fact is, that quality control is an integral part of each process from the beginning and throughout the project. Our quality control includes production supervisors and machine operators who are constantly monitoring and inspecting our work at every stage to maintain the consistent quality agreed upon with our customers.