From product idea to manufacturable plastic product
Creating a plastic product: from idea to series production
Creating a plastic product requires design, material, mould and production process to work together. PEZY guides you from concept and engineering through prototyping and mould making to preparation for series production. With more than thirty years of experience and our own Pilot Factory, we identify risks early and validate decisions before you invest further.
These companies trust PEZY to turn their product ideas into reality.
From product idea to manufacturable plastic product
A strong starting point prevents functionality, cost and production requirements from emerging too late. We translate your idea into a production-oriented design and consider technical feasibility, material selection, injection moulding and circularity as an integrated whole.
Product and use
We investigate who will use the product, the forces it will be subjected to and the environment in which it must function. These scenarios form the basis for the construction, material and test criteria.
Volume and target cost
An annual volume of 500 units requires a different assessment from 50,000 units. We weigh tooling, processing, assembly and unit cost against the expected volume.
Integrating functions
Snap-fit systems, hinges, locking mechanisms, seals and the integration of electronics can all be part of the plastic design. We assess where integration can reduce the number of parts and assembly steps.
Circularity from the outset
We investigate disassembly, recyclability, recycled materials and bio-based materials. A circular choice must suit the application, service life and available collection and processing route.
Engineering and simulations for a reliable design
Simulations help assess the design and production process before the mould is built. They reveal risks but do not replace physical validation. We combine calculations with material data and practical tests.
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Mould flow analysis
We investigate filling, weld lines, air traps and potential warpage. The results support decisions on product geometry, gating and mould construction.
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Strength and stiffness
Finite Element Analysis (FEA) helps assess mechanical behaviour under relevant loads. We use the results to optimise strength, stiffness and material usage, and validate critical assumptions through testing.
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Thermal management and cooling
Cooling channels, wall thicknesses and material affect cooling, warpage and cycle time. By investigating these factors together, we improve the balance between product quality and process costs.
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Draft, venting and tolerances
We assess how the part is released from the mould, where venting is required and how critical dimensions can be achieved. This allows us to prepare the initial injection-moulding trials in a focused manner.
The right plastic for your application
Material selection plays a key role in performance, appearance, service life and cost. We assess strength, stiffness, impact resistance, creep and wear, as well as temperature, chemicals, UV, transparency and any antistatic or flame-retardant properties. Engineering plastics such as PC, PBT and PA are weighed against materials such as PP, PE and ABS based on the specific material grade. Availability, price and circularity are also taken into account. For PCR, bio-based or recyclable plastics, we verify the required properties and intended recycling route. For food contact, medical applications or specific fire-safety requirements, we determine which material data, tests and regulations are relevant; terms such as FDA, UL and REACH are not interchangeable product certifications.
Prototyping and validation before scaling up
A design only becomes meaningful once it has been tested under the right conditions. We build rapid models to assess form and fit, and functional prototypes for more realistic testing. How representative the material and production method are determines which conclusions can be drawn.
Form, fit and assembly
Using 3D-printed models, for example, we assess dimensions, interfaces and the assembly sequence. We feed opportunities for improvement back into the design before the next investment is made.
Performance under load
Depending on the application, we investigate drop loads, vibration, temperature fluctuations, pressure, fatigue and cyclic loading. We define relevant criteria for each test.
User experience
We test operation, grip, closures and everyday use. Feedback helps improve the balance between functionality and ease of use.
Trial injection moulding in our own Pilot Factory
In Groningen, we produce samples on injection-moulding machines. We measure critical properties and adjust the design, tooling or settings when the results call for it. First-time-right is an ambition based on thorough preparation and targeted validation, not a guarantee that the first trial will always succeed without adjustments.
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Mechanical functionality
Using actual injection-moulded parts, we test snap-fit connections, hinges, moving parts and other functions. This also reveals effects that could not be fully assessed in a model or simulation.
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Cycle time and repeatability
We measure cycle time and variation across multiple cycles or trial runs. This helps establish a stable process at an appropriate cost.
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Surface and tolerances
We check critical dimensions, colour, gloss and visible defects such as sink marks and flow lines. The assessment is performed against agreed technical and aesthetic criteria.
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Use and assembly
We evaluate the assembly, closure and use of the complete product. Findings from this practical assessment are incorporated into the release process.
Preparing for series production
After validation, we develop the production approach in greater detail. The design, mould, process and supply chain must work together to meet the agreed volumes and quality. The tooling can be produced in-house or with a manufacturing partner.
DFM and mould design
We optimise the design for manufacturability, cycle time, material waste and the intended service life of the mould. Tooling and implementation are aligned with the product requirements and production volume.
Samples and Golden Sample
Approved samples and a Golden Sample provide a tangible reference. Critical specifications, tolerances and appearance requirements are documented for series production.
Process and quality assurance
We document settings, measurement procedures and inspection agreements. Where relevant, automation, FMEA, PPAP and sector-specific requirements become part of production preparation.
Supply chain and aftercare
We support the coordination of packaging, labelling, inventory, logistics and the first production runs. Production data provides a basis for further improvements and cost reductions.
Why PEZY
Why have your plastic product created by PEZY?
At PEZY, design, engineering, prototyping and production are closely integrated. Our own Pilot Factory in Groningen makes it possible to validate design decisions using actual parts and trial runs. We focus on a reliable, scalable production approach and incorporate circularity where it suits the application. Close collaboration between disciplines ensures that test findings remain connected to the design and mould.
3 locations
Design, engineering and production in close collaboration.
Pilot Factory
From initial model to small series, in-house.
30+ years
Product innovation since 1995.
Great Place to Work
Recognised based on feedback from our employees.
Discuss your plastic product
From an initial idea to a design that needs to be prepared for production: we discuss the application, volumes, material considerations and key risks. This enables us to determine a suitable route towards a tested and manufacturable product.
Contact
Schedule a meeting
Choose a time that suits you. We will discuss your question and the logical next step.