How to Choose Electronics Component Molding?

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You need to be able to source electronic components for your new product that reach your cost, quality, and reliability expectations. In fact, the success of your product is riding on the components that it&#;s made up of being perfect for the job. It&#;s not as simple as just going online and choosing something that works, either. In order to find perfect components, we follow this process&#;

What follows is a summary of the electronic component selection steps, but I discussed it in far more detail on our group&#;s podcast here.

The electronic component selection process is more complex than many people think. Proper electronic component selection is not actually as simple as going to Radio Shack, buying a part, and just using it as long as it works. Today&#;s manufacturers need to make sure that their components to be used in mass production meet certain criteria and there are many elements to consider during the sourcing process. We&#;ve broken the process down into 18 steps&#;

1. Define your Requirements
To define your requirements you&#;ll consider what your product does, its users, the environment it will be in, and how this particular component needs to function in order to help it achieve its goals among others. Each part&#;s cost, specifications, etc, must be noted now, too.

2. Select the Key Components
Key components are those that the product relies upon to function correctly. For electronics, it might be a display, type of chip, enclosure, etc. Without these, you are in trouble so they must be noted and considered with care.

3. Analyze the Operating Environment/s
Note your product&#;s intended operating environments. Components that can handle the environment without failing are crucial, otherwise, the product will be unreliable.

4. Identify Critical Parameters per component
Your requirements will demand that components that work in a specific range must be sourced, therefore you need to work on the range of parameters you need for each part. This might be voltage, tolerances, etc. If you select parts without the right parameters you may find that they fail if the environment alters slightly, such as a power surge, or those that are too highly rated just cost you too much.

5. Source the Components
Sourcing components directly from component manufacturers is usually the best option in terms of cost and reliability of supply. You should always obtain the datasheets and check the specifications against your requirements.

6. Consider the Supply Chain
It will reduce risks of disruption if you choose to source from well-established and professional manufacturers. At the same time, find a second-source supplier, especially for key components, so they can step in and supply you if there is ever a problem with your main pick.

7. Check for Obsolescence
Design engineers should be wary of each part&#;s lifecycle and confirm with the manufacturer that they plan to produce it for the long term. This will reduce the risks of you incorporating a part into your new product that is then suddenly unavailable.

8. Analyze costs
Purchasing components at the right cost impacts the sale price of the product. If you buy in large quantities prices will be far lower, so it&#;s better to find a supplier who can supply your required quantity at a reasonable price.

9. Selecting Components at the right level of Reliability and Quality
To guarantee better reliability you should try to select parts that have a margin of reliability, for example, they can handle temperatures outside of the usual operating environment of the product. To do this, you need to perform reliability testing on samples of the parts.

10. Purchase Second-Source Components
If you have found second-source suppliers for your critical components at least, be sure to purchase some and then if there is an emergency you will already have a supplier who can step in and won&#;t have to do the sourcing process from scratch causing delays.

11. Component Database
Implement a component database and keep it updated with new versions of datasheets, version numbers, etc. Be sure to remove obsolete information so your team only sees up-to-date information about the components.

12. Design for Excellence, especially DFM
Use DfX to design your product with design goals in mind that will reduce risks later on, for example, Design for Manufacturing, or DFM , is a popular principle to embrace because it emphasizes designing the product to be easier and more straightforward to manufacture and at a lower cost.

13. Compliance and Standards
Check each component&#;s datasheet to confirm that it complies with the safety standards and regulations of wherever you intend to sell it. If you unwittingly miss a compliance requirement it&#;s very unlikely you can sell the product which will be a disaster if they&#;re all waiting on the docks in a container.

14. Simulating and Prototyping the Product
Now you can make tangible samples or prototypes. You will use the components to make rough prototypes at first and then, as you iterate the prototypes, they will get closer and closer to production standard. This helps you to qualify and validate the functions, performance, looks, etc, of the product.

15. Documentation and Record-Keeping
The many changes that design engineers make to the product during the development process need to be documented so progress can be tracked and team members know when changes were made. Fixes to problems may be collected in a lessons-learnt database, along with dates, who made a change or fix, etc.

16. Design Reviews
Not long before production starts you will have done a lot of testing on components and prototypes and will be close to satisfied that it looks and works correctly, reaching your goals and expectations. But, before signing off, a design review meeting should be called where all engineers and management examine each part of the product being in mind if it reaches its requirements. The purpose is to validate and verify that the product reaches its requirements for performance, reliability, quality, etc, and functions as expected.

17. Lock the Bill of Materials (BOM)
Before manufacturing the BOM is locked which means that there are no more changes to parts used or designs. Component suppliers are contacted to confirm costs and availability and place orders. Everyone works together to make sure that all of the parts will arrive on time for production to start on a specific date. Then attention turns to setting up the manufacturing assembly line/s, writing SOPs, hiring staff, etc.

18. Pilot Run
Before starting mass production it&#;s the last chance to check that the components you have selected can be used to manufacture the products at scale. For this, use the components that you have, by now, tested and validated in a short pilot run using the same line, staff, equipment, processes, etc, as will be used in mass production. If there are any production issues, packaging problems, etc, you will encounter them now and can fix them before things go any further and you have produced thousands of units of your product.

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Get help

Agilian has a supply chain management team that can assist you in sourcing the ideal components for your needs. Here&#;s how we manage supply chains for you.
If you have any questions about bringing your new product to market, please don&#;t hesitate to get in touch with us&#;we&#;re happy to offer some friendly advice and let you know if and how can help you.

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What are some tips for choosing the right injection molding material?

1. Define project objectives clearly
2. Understand the material properties
3. Consider the production volume and rate
4. Evaluate the overall cost
5. Ensure regulatory compliance
6. Evaluate environmental impact

Overview

• Injection molding is a versatile manufacturing process for creating three-dimensional components by injecting molten material into molds.
• The success of projects hinges on material selection, impacting the final product&#;s quality and durability.
• For precision and excellence in injection molding, Richfields stands ready to assist with injection molding needs.

Injection molding is a highly versatile and widely utilized manufacturing process in which molten material, typically plastic or metal, is injected into a mold cavity under high pressure. Once injected, the material solidifies, taking the shape of the mold, and is then ejected to produce a three-dimensional component or product.

The success of any injection molding project hinges on the careful consideration of the material used, as it directly impacts the quality, durability, and performance of the final output. Our focus will be on providing you with useful tips for choosing the right injection molding material to ensure that your project meets the highest standards of excellence.

Define Project Objectives Clearly

Clarity in project objectives serves as the foundation for successful injection molding. Begin by clearly outlining the goals and expectations of the injection molding project, including specifying design requirements, performance standards, and desired outcomes.

For instance, if the objective is to produce lightweight, impact-resistant components for consumer electronics, such as smartphone accessories, the material choice may lean towards high-strength plastics with excellent impact resistance.

Understand Material Properties

Material properties directly influence the product&#;s functionality, lifespan, and overall performance. A thorough understanding helps select a material that aligns with the desired product attributes, such as the physical, mechanical, and thermal characteristics of potential injection molding materials.

If the project requires a material with high chemical resistance for automotive components, selecting a polymer like polypropylene may be suitable due to its corrosion-resistant properties. Therefore, conducting material testing, consulting material datasheets, and leveraging the expertise of material engineers is important to gain more insights.

Consider the Production Volume and Rate

Production volume and rate consideration involves evaluating the scale and speed at which the injection molding process will occur. These factors impact material selection, as high-volume production may require materials with faster cycle times and increased durability.

For mass production of consumer goods, such as food packaging, a material with quick cooling properties, like certain thermoplastics, might be preferable to expedite production cycles.

Evaluate the Overall Cost

Cost considerations are also essential for project budgeting and determining the feasibility of the injection molding process. Therefore, evaluating the overall cost should involve a comprehensive analysis of material costs, production costs, and any post-processing expenses associated with the chosen material.

While a high-performance engineering polymer may have a higher initial cost, it could lead to long-term savings by reducing product failures and minimizing the need for costly post-processing.

Ensure Regulatory Compliance

Ensuring regulatory compliance is a crucial step in the injection molding process. It involves carefully verifying that the chosen material aligns with industry regulations, standards, and legal requirements. This is incredibly important as it helps prevent potential legal issues and product recalls, ensuring that the final product is safe and of high quality.

A notable example of this can be seen in the medical industry. When it comes to medical devices like surgical tools and diagnostic equipment, it is essential that the materials used in injection molding adhere to strict guidelines, such as those set by the Food and Drug Administration (FDA).

Evaluate Environmental Impact

With an increasing focus on environmental responsibility, considering the ecological footprint of materials on the planet is essential for a socially responsible manufacturing approach. Opting for recyclable and biodegradable materials aligns with eco-conscious practices and supports sustainable manufacturing.

To progress in this direction, start by collaborating with environmental specialists and suppliers to assess the ecological impact of potential materials. Ensure utilization of materials that minimize environmental harm, supporting a green approach to injection molding.

Common Materials for Injection Molding

Injection molding is a precise manufacturing process that accommodates a wide range of materials, each chosen based on the specific requirements of the end product.

Commonly employed materials include polyethylene (PE) and polypropylene (PP), prized for their chemical resistance and affordability, making them ideal for applications in packaging, toys, and medical devices. Meanwhile, acrylonitrile butadiene styrene (ABS) finds utility in consumer electronics and automotive components due to its exceptional impact resistance and machinability.

Polycarbonate (PC) offers high optical clarity and heat resistance, making it suitable for optical discs and electronic components. Additionally, polyethylene terephthalate (PET), known for its transparency and lightweight nature, finds extensive use in bottles and textile fibers.

Key Takeaway

Following these tips for choosing the right injection molding material is a critical decision that directly influences the success of your project. It ensures not only the functionality and durability of the final product but also contributes to the overall efficiency of the process.

With a focus on customer service, competitive pricing, and a wide product offering, Richfields ensures your injection molding needs are met with precision and quality. Contact us for a quote today and experience firsthand the excellence we bring to every project.

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