A large number of plastic injection molding parts are manufactured as components of a larger assembly of products.When using molded plastic components, it is possible to combine them or use other components that use a different material to make the final product strong or versatile.
Assembling the product using knuckles, bolts, or nuts that are mechanically continuous with one another is important, so it will assure its structural integrity and ensure that it does not fail in the future.It is often necessary to assemble the product as a process of secondary manufacturing in order for it to be used in the final product.
Some consumers are obligated to assemble the goods while in other cases it is shifted to the Assembly of injection molding Plastic Parts manufacturer.
Manufacturers generally would like their products to contain as few parts and materials as possible, in order to simplify the assembly process and minimize the costs involved in the manufacture and assembly of their product.In designing plastics products, it is a major objective to minimize assembly time by reducing the number of components and integrating the fasteners directly into the plastic parts themselves.
Injection molding processes are usually employed to produce plastic parts for use as components of the Design for Assembly process. This is so that components of extremely complex geometries can be produced.
The Design for Assembly philosophy emphasizes products ought to be designed based on how they are going to be assembled, in order to reduce manufacturing costs and improve product quality.
Even the smallest reduction in assembly time, handling costs, equipment, and labor fees can have a significant impact on the bottom line while other parameters are accounted for, such as handling costs, assembly time, equipment, and labor costs.
An integral part of the DFA is its simplicity.
By incorporating as many features of an assembly as possible into the molded parts, manufacturers are able to reduce the number of parts required for production of the component.
It is imperative to use fasteners, such as screws, inserts, and the like so as not to exacerbate an already difficult situation and also with the intention of avoiding the use of mechanical fasteners, and other assembly operations including adhesive bonding and welding.
However, this could prove challenging in the real world.
Another reason is that the ability to manufacture a part also depends heavily on the complexity of its structure. Thus, it stands to reason that complex parts will be more challenging to tool and to manufacture.
The cost savings will be offset by a higher initial tooling investment and more complicated assembly operations, as well as more complex primary molding operations. As tool complexity increases, mold reliability and mold repair and maintenance are more important issues.
A competitive fastening system may not provide superior quality to a component produced with a proprietary fastener.
For example, the design of molded cantilever-snap beams directly into molded products allows the designer to eliminate the need for self-threading screws.
The molded snap beam assembly method is advantageous because it eliminates one component, the self threading screw, and simplifies assembly by eliminating the need for rotation and replacing it with an assembly which can be assembled simply by pushing on the bolt head.