Designing Plastic Prototypes: Key Considerations in 2025

 


Choosing the right material is a strong starting point when building a prototype plastic part because it helps ensure that your mold produces consistent, high-quality results. But material alone won’t guarantee success. Several other factors can affect the outcome. Let’s break them down.

Manufacturing methods for plastic prototypes

Plastic prototyping has become faster and more affordable thanks to newer technologies. 3D printing is one of the most accessible options, letting teams test multiple design versions quickly without driving up costs.

CNC machining, by contrast, offers tighter tolerances and uses production-grade plastics, making it a better fit when you need a prototype that closely mirrors the final part. It’s ideal for evaluating fit, function, and durability under real-world conditions.

Choosing the right materials

Your choice of material can directly impact the mold performance and the quality of the prototype plastic part.

When deciding on a resin, it’s important to weigh factors like cost and the material’s properties under pressure. You’ll need to consider how a resin reacts to heat and whether it works well with other materials used during production (such as aluminum or other plastics).

Correct gate placement

Gates are the channels where molten plastic enters the mold cavity under high pressure, so their placement is crucial. There’s no universal rule for positioning these entry points, so plan your part’s design to accommodate them.

Edge thickness

While they seem like minor details, edge and wall thickness can significantly impact the quality of your prototype plastic part. Uneven wall thickness causes inconsistent cooling during molding, which creates internal stress and voids. These defects can weaken the part or distort its shape, or even prevent it from filling the mold completely. Corners or joints are particularly vulnerable to stress and deformation if they’re too thin.

As a general guideline, corners on the part’s overall wall dimension should be between 90% and 120% thick to reinforce the structure. At the same time, it will allow a consistent flow and cooling.

Your prototyping partner

A strong design only goes so far without the right team behind it. When creating a prototype plastic part, it’s important to work with a manufacturer who understands your goals and has the tools and experience to support them.

That’s where we at HLH Prototypes come in. Our team combines deep technical know-how with advanced technologies to help turn your concept into a working part. Ready to get started? Reach out for a free project review. Fill out our form online or contact us at FreeQuote@HLHPrototypes.com.

Source URL: https://www.hlhprototypes.com/designing-plastic-prototypes-key-considerations-in-2025/

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