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. Material Selection: 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, appearance, and ability to mimic the final product.

Common Materials for Plastic and Electronic Prototypes

Selection Tips

When picking a material, focus on four factors:

• Mechanical Properties: Will the prototype need to withstand pressure or impacts? For example, a phone case prototype needs ABS or PC for impact resistance.
• Corrosion Resistance: If the prototype touches chemicals (like ink or cleaning fluids), choose PP or nylon.
• Heat Resistance: For parts near heat sources (e.g., laptop vents), PC is a better choice than ABS.
• Biocompatibility: For prototypes used near skin (e.g., smartwatch bands), pick materials with low toxicity.

Case: 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. Data Collection: Lay the Groundwork for Precision

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.

Key Data Collection Steps

1. Import 3D Drawing Files: Ask the client for 3D CAD files (e.g., STEP or IGES formats). These files are the blueprint for machining—import them into CAM (Computer-Aided Manufacturing) software to plan tool paths and cutting steps. For example, 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 (e.g., 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. CNC Machining: 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: Adjust spindle speed (e.g., 3,500 RPM for ABS, 2,800 RPM for PC) and feed rate (e.g., 450 mm/min for soft plastics, 350 mm/min for rigid plastics) based on the material.

2. Multi-Axis Machining: For complex parts (e.g., a curved smartwatch case), use 5-axis CNC machines. 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%.

Example: 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. Post-Processing: Polish and Perfect Your Prototype

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

Post-Processing Steps

• 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 (e.g., remote controls) to prevent scratches.
• Surface Treatment:
• Painting: Apply electronic-grade paint (e.g., matte black for router enclosures) to match the final product’s color and protect against scratches.
• Silk Screening: Add labels (e.g., brand logos, button icons) for clarity. For example, a TV remote prototype had “Power” and “Volume” icons silk-screened onto the buttons.
• Electroplating: For parts that need conductivity (e.g., USB port brackets), add a thin nickel or copper coating to the surface.

5. Assembly Testing: 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.

Testing Steps

1. Test Assembly: Put all prototype parts together to check:

• Fit Accuracy: Do parts align? For example, a phone case prototype should snap onto the phone without gaps.
• Mold Quality: Are there any defects (like warping) from machining that stop parts from fitting?

2. Functional Testing: Test the prototype under real-world conditions:

• Structural Stability: Drop the prototype from 1m (simulating a fall) to see if it breaks.
• Mechanical Performance: For moving parts (e.g., 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) or 90% humidity to test durability.

Case: A prototype of a water-resistant Bluetooth speaker (made from PP) underwent functional testing. It was submerged in 1m of water for 30 minutes—no water leaked inside, and the speaker still worked. This confirmed the prototype met the company’s water-resistance standards.

6. Packaging and Shipping: Deliver Your Prototype Safely

The final step in the processing process of plastic and electronic product prototype models is packaging and shipping. Proper packaging ensures the prototype arrives undamaged.

Packaging and Shipping Tips

• Safe Packaging: Use foam inserts and rigid cardboard boxes to cushion the prototype. For fragile parts (e.g., 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 (e.g., 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. For urgent projects (e.g., 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

At Yigu Technology, we know the 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 (e.g., 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.

FAQ

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

A: PMMA (Acrylic) is the best choice—it has 92% light transmission, 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: It depends on complexity. A simple ABS enclosure (e.g., a small sensor housing) takes 4–6 days (from material selection to shipping). A complex 5-axis machined PC prototype (e.g., a laptop case) takes 8–12 days, including gypsum sampling and functional testing.

3. Q: Can CNC machining make prototypes with small holes (e.g., 0.5mm in diameter)?

A: Yes. 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.