The Production of Plastic Parts: From Idea to Finished Product

Before a plastic part ever reaches an assembly line or fulfillment center it goes through a precise, multi-stage production process. When clients understand this process, it helps them set realistic timelines, ask better questions, and avoid costly surprises. 

From the design stage to the production stage, we’re walking you through the production of a plastic part so you can approach your plastic injection molding project with confidence. 

Stage 1: Design & DFM Review 

Stage one of the production of plastic parts begins with submitting a CAD file or a concept drawing. Our team of designers then conducts a design-for-manufacturing (DFM) review, where we flag common issues like draft angles, wall thickness, or undercuts. 

This stage is the foundation of your plastic part. It’s where we make necessary adjustments so we can avoid any potential costly changes after the tooling is produced, and ensure your part is optimized for efficient production. 

Once we’re finished with your design, it’s time to start the tooling development process. 

Stage 2: Tooling 

In stage two we begin the process of getting your mold (also referred to as your tooling) created. We do this by partnering with one of our trusted American tooling manufacturers, handling all communication to ensure your tooling is developed to the DFM design specifications we finalized. 

The lead time for a tooling piece is typically 4-16 weeks, depending on the complexity of the plastic part. Your tooling piece is the largest upfront cost of the process, but it’s usually a one-time investment as long as the design process is completed thoroughly to avoid costly mistakes. 

For certain plastic parts that are more complicated, you may want to order a tooling sample. It’s made out of a cheaper material and is an affordable way to test the specs of your part before the final tool is produced. Once your tooling is built it can produce thousands of plastic parts, making it one of the most important pieces of the production process. 

As experts in the industry with trusted manufacturers we’ve worked with for decades, our team ensures your design and expectations are communicated clearly and your tooling is created to standard from the start. 

Stage 3: Sampling & Initial Run 

If your part requires a tooling sample to be produced first, once it arrives initial parts are created using one of our well-maintained plastic injection molding machines and are measured against engineering specs. This is the time in the process where we check the dimensions, tolerances, and appearances. 

Depending on if your tooling requires adjustments, we make those before your final tooling piece is produced. 

Once we receive the tooling sample or your final mold, we make sure your plastic part sample is approved and signed off on before getting production officially started. 

Stage 4: Production

Now that the design and tooling production are completed and the sample is approved, full production runs can begin. 

At this point the cycle time and process parameters are locked in and confirmed, and once production is underway quality checks are continuously performed throughout. Each part is inspected, and then they are packaged and prepared for delivery. 

Our team maintains our equipment, your tooling piece, and we always ensure consistent, reliable parts are produced at scale. 

Stage 5: Ongoing Partnership

We safely store your tooling and maintain it for future runs when the time arrives. Our team closely monitors your project’s results, and takes all feedback into consideration to ensure reorders are produced faster and more cost-effective than the initial run. 

It’s important that data is tracked and any issues are flagged throughout the process. As we maintain our long-term supplier relationship, we want to feel confident it delivers our client real value — especially for the contractors managing ongoing fulfilment. 

Conclusion

Knowing this process puts buyers in a stronger position as they plan projects, budget for production, and can assist in selecting the right plastic injection molding company. 

At Camcar Plastics, we walk every customer through this process from day one. Whether you're developing a new part or looking for a more reliable supplier, we’re confident our decades of experience can get you where you need to be. Contact us here to get started.