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Expertise

Prototyping plastic parts

Q: What is the difference between a prototype and a pre-production run?

The Plastic prototype serves to validate the concept, the parameters of thermoforming and the technical characteristics of the part. The Plastic pre-series allows checking the repeatability of the process and the stability of performance over several cycles before industrial production.

Q: How long does the prototyping phase last?

The average duration varies between one and three weeks depending on the complexity of the product, the technical requirements, the expected accuracy and the level of adjustment required on the tooling or the forming cycle, based on your feedback.

Q: Are the prototypes made using the definitive materials?

Yes. The prototypes are made with the final matters , the same thicknesses and thermoforming conditions as those planned for the series are applied, ensuring perfect representativeness of the results.

Following the design and manufacture of the tooling, the phase prototype allows for the production of representative parts while limiting investment through the use of resin or wooden tooling. The aim of this phase is to bring a product design to maturity before launching into heavier industrial investments.

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Why implement plastic prototyping for an industrial project?

The plastic prototyping is a exploratory phase, which can be mobilised before industrialisation.

prototype is a Agile solution, which allows limit investment thanks to the validation of the main manufacturing outlines. It is particularly used when a product, design, or concept is not completely defined or finalised. This phase allows for the validation, among other things, of the thickness distribution, the mechanical outfit, the material stability, the Surface finish, the clipping masks and compatibility with the’assembly. This step allows us to anticipate production risks and adjust the product if necessary, before the series production.At RBL Plastics, we produce the prototypes on the same equipment base as the industrial series.

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Testing performance in real-world conditions

Verify the behaviour and reliability of the industrial plastic prototype.

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Optimising thermoforming parameters

Adjust the product, design, and shapes before mass launch.

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Ensure final product compliance

Ensure the launch of industrial investments without major risks.

The 5 key steps to carry out your plastic prototyping

1 - Preparation of trials

The preparation of the tests begins with the installation of the tooling on the thermoforming machines and the initial parameter configuration (temperature, heating time, vacuum sequences, cooling, forming depth and pull settings).

These values are defined from simulations and assumptions from previous steps, particularly during the design phase. This conditioning allows for the accurate reproduction of the future environment. series production, ensuring the prototype perfectly reflects the final behaviour of the thermoformed plastic part. The objective is to create a technical context identical to that of the production cycle to ensure consistent and reliable validation.

2 - Prototype realisation

The first pieces are then thermoformed from the definitive mould. These plastic prototypes allow us to observe the way matter is distributed, to assess its mechanical outfit, to analyse the thickness distribution, to judge the visual rendering.

During this step, the Masking is carried out on machining centres 3 and 5 axes, which allows for the validation of tolerances, geometric accuracy, and compatibility with the Assembly operations.

3 - Validation technique

Once the prototypes have been produced, the quality teams proceed with Dimensional measurements accurate, in comparison with the approved plan, and in the study of potential deviations.

You then receive the prototypes and plastic pre-series to carry out your own functional or integration tests. This phase will allow you to verify that the part meets all your technical, mechanical, visual, and usage requirements. Once validation is obtained, the parameters are consolidated and serve as the basis for future Plastics industrialisation.

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Why call on RBL Plastiques for this expertise?

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Certified process

Certified ISO 9001 and 50001, we guarantee sustainable production that complies with industrial constraints.

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At the cutting edge of innovation

Through our research and development department, benefit from the latest innovations in thermoforming and plastic technology.

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A team of experts

We provide you with a team of experts and engineers from the design to the industrialization of your project.

# Conception / Manufacturing

$ Industrialization

We are replying to your questions

What is the difference between a prototype and a pre-production run?

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K

The Plastic prototype serves to validate the concept, the parameters of thermoforming and the technical characteristics of the part. The Plastic pre-series allows checking the repeatability of the process and the stability of performance over several cycles before industrial production.

How long does the prototyping phase last?

L

K

The average duration varies between one and three weeks depending on the complexity of the product, the technical requirements, the expected accuracy and the level of adjustment required on the tooling or the forming cycle, based on your feedback.

Are the prototypes made using the definitive materials?

L

K

Yes. The prototypes are made with the final matters, the same thicknesses and thermoforming conditions as those planned for the series are applied, ensuring perfect representativeness of the results.

Contact our experts now

Enjoy a complimentary initial consultation with our team of experts.

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