Guide to Processing Process of Plastic and Electronic Product Prototype Models

The 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. 材料の選択: 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, 外観, and ability to mimic the final product.

Common Materials for Plastic and Electronic Prototypes

選択のヒント

When picking a material, focus on four factors:

• 機械的特性: Will the prototype need to withstand pressure or impacts? 例えば, a phone case prototype needs ABS or PC for impact resistance.
• 耐食性: If the prototype touches chemicals (like ink or cleaning fluids), choose PP or nylon.
• 耐熱性: For parts near heat sources (例えば。, laptop vents), PC is a better choice than ABS.
• 生体適合性: For prototypes used near skin (例えば。, smartwatch bands), pick materials with low toxicity.

場合: 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. データ収集: 正確な基礎を築きます

Accurate data ensures your prototype matches the original design. This step in the processing process of plastic and electronic product prototype models involves gathering design files and creating test samples to confirm accuracy.

重要なデータ収集手順

1. Import 3D Drawing Files: Ask the client for 3D CAD files (例えば。, ステップまたはIGES形式). これらのファイルは、機械加工用の青写真です。 (コンピューター支援の製造) software to plan tool paths and cutting steps. 例えば, 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: 3Dファイルを使用して、石膏サンプルを作成します. Gypsum is cheap and easy to shape, so it’s ideal for checking:

• 形状の精度: Does the sample match the design’s curves and edges?
• 曲率の​​一貫性: Are rounded parts smooth (no bumps or flat spots)?
• 標準コンプライアンス: Does the sample meet size requirements (例えば。, a 100x50x10mm enclosure)?

なぜ石膏サンプルが重要なのか: 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 やり直しの日.

3. CNC加工: 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: 調整する spindle speed (例えば。, 3,500 RPM for ABS, 2,800 RPM for PC) そして フィードレート (例えば。, 450 ソフトプラスチックのmm/min, 350 mm/min for rigid plastics) based on the material.

2. マルチ軸の機械加工: 複雑な部品の場合 (例えば。, a curved smartwatch case), 5軸CNCマシンを使用します. 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%.

例: 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. 後処理: Polish and Perfect Your Prototype

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

後処理ステップ

• 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 (例えば。, リモートコントロール) 傷を防ぐため.
• 表面処理:
• 絵画: Apply electronic-grade paint (例えば。, matte black for router enclosures) to match the final product’s color and protect against scratches.
• シルクスクリーニング: ラベルを追加します (例えば。, brand logos, button icons) 明確にします. 例えば, a TV remote prototype had “Power” and “Volume” icons silk-screened onto the buttons.
• 電気めっき: For parts that need conductivity (例えば。, USB port brackets), add a thin nickel or copper coating to the surface.

5. アセンブリテスト: 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.

テスト手順

1. テストアセンブリ: Put all prototype parts together to check:

• 精度を適合させます: Do parts align? 例えば, a phone case prototype should snap onto the phone without gaps.
• Mold Quality: Are there any defects (反りのように) from machining that stop parts from fitting?

2. 機能テスト: Test the prototype under real-world conditions:

• 構造安定性: プロトタイプを1Mから削除します (simulating a fall) to see if it breaks.
• 機械的性能: For moving parts (例えば。, 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) または 90% humidity to test durability.

場合: A prototype of a water-resistant Bluetooth speaker (made from PP) underwent functional testing. 1mの水に沈められました 30 議事録 - 水が漏れていません, and the speaker still worked. This confirmed the prototype met the company’s water-resistance standards.

6. パッケージングと配送: Deliver Your Prototype Safely

の最後のステップ processing process of plastic and electronic product prototype models パッケージングと配送です. Proper packaging ensures the prototype arrives undamaged.

パッケージングと配送のヒント

• 安全なパッケージ: Use foam inserts and rigid cardboard boxes to cushion the prototype. 壊れやすい部分の場合 (例えば。, PMMA display covers), add a layer of bubble wrap and label the box “Fragile—Electronic Prototype.”
• ロジスティクス選択: Choose a logistics provider with experience shipping electronic prototypes (例えば。, 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. 緊急プロジェクトのために (例えば。, 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

Yiguテクノロジーで, 私たちは知っています 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 (例えば。, 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.

よくある質問

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

a: PMMA (アクリル) is the best choice—it has 92% 光伝達, which is close to glass. It’s also scratch-resistant, making it ideal for transparent parts like display covers or LED light housings.

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

a: 複雑さに依存します. A simple ABS enclosure (例えば。, a small sensor housing) takes 4–6 days (from material selection to shipping). A complex 5-axis machined PC prototype (例えば。, a laptop case) takes 8–12 days, including gypsum sampling and functional testing.

3. Q: Can CNC machining make prototypes with small holes (例えば。, 0.5直径のmm)?

a: はい. 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.