دليل معالجة عملية النماذج النموذجية البلاستيكية والإلكترونية

ال processing process of plastic and electronic product prototype models is a high-precision, efficient manufacturing workflow. It’s key to verifying whether electronic product designs are feasible and functional—all while keeping costs low and providing reliable data for mass production. This guide breaks down each step of the process, with real examples and data to help you avoid common pitfalls and create high-quality prototypes.

1. اختيار المواد: Choose the Right Base for Your Prototype

Selecting the correct material is the first critical step in the processing process of plastic and electronic product prototype models. The material directly impacts the prototype’s durability, مظهر, and ability to mimic the final product.

Common Materials for Plastic and Electronic Prototypes

نصائح الاختيار

When picking a material, focus on four factors:

• الخصائص الميكانيكية: Will the prototype need to withstand pressure or impacts? على سبيل المثال, a phone case prototype needs ABS or PC for impact resistance.
• مقاومة التآكل: If the prototype touches chemicals (like ink or cleaning fluids), choose PP or nylon.
• مقاومة الحرارة: For parts near heat sources (على سبيل المثال, laptop vents), PC is a better choice than ABS.
• التوافق الحيوي: For prototypes used near skin (على سبيل المثال, smartwatch bands), pick materials with low toxicity.

قضية: A tech company needed a prototype for a wireless speaker enclosure. They chose ABS for its easy machining and moderate impact resistance—perfect for testing how the enclosure would hold up to drops. The prototype matched the final product’s look and durability, and machining took 30% less time than it would have with PC.

2. جمع البيانات: وضع الأساس للدقة

تضمن البيانات الدقيقة أن النموذج الأولي الخاص بك يطابق التصميم الأصلي. This step in the processing process of plastic and electronic product prototype models involves gathering design files and creating test samples to confirm accuracy.

Key Data Collection Steps

1. Import 3D Drawing Files: Ask the client for 3D CAD files (على سبيل المثال, خطوة أو تنسيقات IGES). These files are the blueprint for machining—import them into CAM (التصنيع بمساعدة الكمبيوتر) software to plan tool paths and cutting steps. على سبيل المثال, a prototype of a wireless charger required a STEP file with 0.03mm dimensional tolerances to ensure the charging coil would fit inside.
2. Create Gypsum Samples: Use the 3D files to make a gypsum sample. Gypsum is cheap and easy to shape, so it’s ideal for checking:

• Shape Accuracy: Does the sample match the design’s curves and edges?
• Curvature Consistency: Are rounded parts smooth (no bumps or flat spots)?
• Standard Compliance: Does the sample meet size requirements (على سبيل المثال, a 100x50x10mm enclosure)?

Why Gypsum Samples Matter: A team working on a tablet prototype found a 0.4mm error in the gypsum sample’s corner curvature. They fixed the CAD file before machining plastic—saving $1,500 in wasted PC material and 2 days of rework.

3. تصنيع CNC: Turn Plastic into a Prototype

CNC machining is the core of the processing process of plastic and electronic product prototype models. It uses computer-controlled tools to cut plastic into the exact shape you need, with high accuracy and smooth surfaces.

CNC Machining Workflow

1. Programming and Setup:

• Use CAM software to generate tool paths—these tell the machine where to cut to remove excess plastic and keep the product shape.
• Set cutting parameters: يُعدِّل spindle speed (على سبيل المثال, 3,500 RPM for ABS, 2,800 RPM for PC) و معدل التغذية (على سبيل المثال, 450 مم/دقيقة للبلاستيك اللين, 350 mm/min for rigid plastics) based on the material.

2. تصنيع متعدد المحاور: للأجزاء المعقدة (على سبيل المثال, a curved smartwatch case), استخدم آلات CNC 5 محاور. These machines can reach all sides of the plastic, so you don’t need to reposition the material. This improves precision by up to 25% compared to 3-axis machines and cuts machining time by 20%.

مثال: A manufacturer made a PC prototype for a laptop trackpad using a 5-axis CNC machine. The tool path was programmed to cut the trackpad’s curved edges and small mounting holes—resulting in a prototype with ±0.02mm accuracy, which fit perfectly into the laptop’s body during testing.

4. ما بعد المعالجة: Polish and Perfect Your Prototype

Post-processing improves the prototype’s appearance and durability, making it look and feel like the final product.

خطوات ما بعد المعالجة

• deburring: Use 400-grit sandpaper or a deburring tool to smooth out tool marks and sharp edges. This is crucial for prototypes people will touch (على سبيل المثال, عناصر التحكم عن بُعد) لمنع الخدوش.
• المعالجة السطحية:
• تلوين: Apply electronic-grade paint (على سبيل المثال, matte black for router enclosures) to match the final product’s color and protect against scratches.
• فحص الحرير: إضافة الملصقات (على سبيل المثال, brand logos, button icons) من أجل الوضوح. على سبيل المثال, a TV remote prototype had “Power” and “Volume” icons silk-screened onto the buttons.
• الطلاء الكهربائي: For parts that need conductivity (على سبيل المثال, USB port brackets), add a thin nickel or copper coating to the surface.

5. اختبار التجميع: Ensure Your Prototype Works

Assembly testing checks if the prototype fits together properly and functions as intended—this is a key step in the processing process of plastic and electronic product prototype models.

خطوات الاختبار

1. اختبار التجميع: Put all prototype parts together to check:

• دقة ملائمة: Do parts align? على سبيل المثال, a phone case prototype should snap onto the phone without gaps.
• Mold Quality: Are there any defects (مثل تزييف) from machining that stop parts from fitting?

2. اختبار وظيفي: Test the prototype under real-world conditions:

• الاستقرار الهيكلي: إسقاط النموذج الأولي من 1M (simulating a fall) to see if it breaks.
• الأداء الميكانيكي: For moving parts (على سبيل المثال, headphone hinges), open and close them 100 times to check for wear.
• Environmental Resistance: Expose the prototype to 85°C heat (simulating a hot car) أو 90% humidity to test durability.

قضية: A prototype of a water-resistant Bluetooth speaker (made from PP) underwent functional testing. تم غمره في 1M من الماء 30 دقائق - لم تسرب الماء إلى الداخل, and the speaker still worked. This confirmed the prototype met the company’s water-resistance standards.

6. التغليف والشحن: Deliver Your Prototype Safely

الخطوة الأخيرة في processing process of plastic and electronic product prototype models is packaging and shipping. Proper packaging ensures the prototype arrives undamaged.

Packaging and Shipping Tips

• عبوة آمنة: Use foam inserts and rigid cardboard boxes to cushion the prototype. للأجزاء الهشة (على سبيل المثال, PMMA display covers), add a layer of bubble wrap and label the box “Fragile—Electronic Prototype.”
• Logistics Selection: Choose a logistics provider with experience shipping electronic prototypes (على سبيل المثال, DHL or FedEx). Track the shipment in real time to know when it will arrive.
• Delivery Time Planning: Work with the client to set a realistic delivery date. للمشاريع العاجلة (على سبيل المثال, a prototype for a trade show), use expedited shipping—but don’t skip safe packaging.

Yigu Technology’s Perspective on Processing Process of Plastic and Electronic Product Prototype Models

في Yigu Technology, نحن نعرف processing process of plastic and electronic product prototype models requires precision and material expertise. Many clients struggle with choosing the wrong material or machining errors—our solution is pairing tailored material advice (على سبيل المثال, ABS for enclosures, PC for high-stress parts) with 5-axis CNC machines (±0.01mm accuracy). We also offer in-house gypsum sampling to catch design flaws early, cutting rework time by 35%. Our post-processing team uses electronic-grade paints and coatings, ensuring prototypes meet industry standards. We deliver high-quality prototypes on time, helping clients speed up their product development cycles.

التعليمات

1. س: Which material should I use for a prototype that needs to be transparent?

أ: PMMA (الأكريليك) is the best choice—it has 92% انتقال الضوء, which is close to glass. It’s also scratch-resistant, making it ideal for transparent parts like display covers or LED light housings.

2. س: How long does the entire processing process of plastic and electronic product prototype models take?

أ: ذلك يعتمد على التعقيد. A simple ABS enclosure (على سبيل المثال, a small sensor housing) takes 4–6 days (from material selection to shipping). A complex 5-axis machined PC prototype (على سبيل المثال, a laptop case) takes 8–12 days, including gypsum sampling and functional testing.

3. س: Can CNC machining make prototypes with small holes (على سبيل المثال, 0.5ملم في القطر)?

أ: نعم. Modern CNC machines can drill holes as small as 0.1mm with high accuracy. For 0.5mm holes (common in electronic prototypes like sensor brackets), we use specialized small-diameter drills and adjust the feed rate to 200–250 mm/min to avoid breaking the tool.