From product idea to manufacturable plastic product
Getting a plastic product made: from idea to series production
Getting a plastic product made requires alignment between design, material, mould and production process. PEZY guides you from concept and engineering to prototyping, mould making and the preparation of series production. With more than thirty years of experience and our own Pilot Factory we investigate risks early and validate choices before you invest further.
These companies rely on PEZY to turn their product into reality.
From product idea to a manufacturable plastic product
A strong starting point prevents functionality, cost and production requirements from only becoming apparent late in the process. We translate your idea into a production-oriented design and investigate technical feasibility, material selection, injection moulding and circularity in conjunction.
Product and use
We investigate who will use the product, what forces will act on it and in what environment it must operate. Those scenarios form the basis for the construction, material selection and test criteria.
Volume and cost target
A run of 500 units per year requires different trade-offs than 50,000 units. We weigh tooling, machining, assembly and price against the expected volume.
Integrating functions
Snap-fits, hinges, locks, seals and electronic integration can be part of the plastic design. We assess where integration can save parts and assembly steps.
Circularity from the start
We examine disassembly, recyclability, recycled and bio-based materials. A circular choice must suit the product’s use, lifespan and the available collection and processing routes.
Engineering and simulations for a reliable design
Simulations help to assess the design and production process before mould making. They reveal risks but do not replace physical validation. We combine calculations with material data and practical trials.
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Mould-flow analysis
We investigate filling, weld lines, air entrapment and possible warpage. The results support decisions about product geometry, gating and mould construction.
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Strength and stiffness
Finite Element Analysis (FEA) helps to assess mechanical behaviour under relevant loads. We use the outcomes to align strength, stiffness and material usage and validate critical assumptions with tests.
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Thermal management and cooling
Cooling channels, wall thicknesses and material influence cooling, warpage and cycle time. By examining these factors together we improve the balance between product quality and process costs.
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Demoulding, venting and tolerances
We assess how the part is released from the mould, where venting is required and how critical dimensions can be maintained. That prepares the initial injection trials in a focused way.
The right plastic for your application
Material selection helps determine performance, appearance, lifespan and cost. We assess strength, stiffness, impact resistance, creep and wear, as well as temperature resistance, chemicals, UV, transparency and any antistatic or flame‑retardant properties. Engineering plastics such as PC, PBT and PA are weighed against materials like PP, PE and ABS based on the specific material grade. Availability, price and circularity are factors. For PCR, biobased or recyclable plastics we verify the required properties and the intended recycling route. For food contact, medical applications or specific fire‑safety requirements we identify which material data, tests and regulations are relevant; terms such as FDA, UL and REACH are not interchangeable product certificates.
Prototyping and validation before scaling up
A design only becomes meaningful when it is tested under the right conditions. We build rapid models for shape and fit and functional prototypes for more realistic testing. The representativeness of the material and manufacturing technique determines what conclusions you can draw.
Form, fit and assembly
With, for example, 3D-printed models we assess dimensions, interfaces and the assembly sequence. We feed improvements back into the design before the next investment is made.
Performance under load
Depending on the application we investigate drop impact, vibrations, temperature variations, pressure, fatigue and cyclic loading. For each test we define the relevant criteria.
User experience
We evaluate operation, grip, closures and everyday use. Feedback helps to improve the balance between functionality and ease of use.
Trial 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 results warrant it. First-time-right is an aim focused on thorough preparation and targeted validation, not a guarantee that a first trial will always succeed without adjustment.
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Mechanical functionality
With real injection-moulded parts we test snap fits, 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 reproducibility
We measure cycle time and variation over multiple cycles or trial runs. That helps establish a stable process with an appropriate cost price.
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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 made against agreed technical and aesthetic criteria.
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Use and assembly
We evaluate assembly, closure and the use of the complete product. Findings from this practical inspection are incorporated into the approval.
Preparation for series production
After validation we further develop the production approach. Design, mould, process and supply chain must all align with the agreed volumes and quality. The tooling can be realised in-house or with a production partner.
DFM and mould design
We optimise the design for manufacturability, cycle time, material waste and the intended life of the mould. Tooling and execution are matched to product requirements and volume.
Samples and Golden Sample
Approved samples and a Golden Sample provide a tangible reference. Critical specifications, tolerances and aesthetic requirements are recorded for series production.
Process and quality assurance
We record settings, measurement procedures and inspection agreements. Where relevant, automation, FMEA, PPAP and sector-specific requirements become part of the production preparation.
Supply chain and aftercare
We support the coordination of packaging, labelling, inventory, logistics and the first production runs. Production data offer points of departure for further improvement and cost reduction.
Why PEZY
Why have a plastic product made at PEZY?
At PEZY, design, engineering, prototyping and production are integrated. Our own Pilot Factory in Groningen allows us to validate design choices with real parts and pilot runs. We focus on a reliable, scalable production approach and incorporate circularity where it suits the application. With short lines of communication between disciplines, test findings remain connected to design and tooling.
3 locations
Design, engineering and production in close collaboration.
Pilot Factory
From first 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 preparing for production: we discuss the application, volumes, material considerations and key risks. That lets us determine the right route to a tested and manufacturable product.
Contact
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