A Comprehensive Approach to Plastic Part Optimization
Designing a part that is robust, functional, and manufacturable can be a challenge. Part designs for polymeric materials can be even more difficult given the time and temperature behavior dependencies of these materials as well as their sensitivities to environmental factors including, chemicals, humidity, and ultraviolet light. We offer extensive design review services as the staff at The Madison Group has a broad and deep understanding of the most important aspects of design required to ensure part success. Our team has the capabilities and tools to predict how easily a design can be manufactured, its robustness, how it will respond during assembly, while in service, and how it will perform over its lifetime.
The scope of our design reviews can be uniquely tailored to meet the needs of our clients and may include:
- Material review and characterization
- Part geometry optimization
- Stress calculations
- Structural analysis (FEA)
- Design for manufacturing and assembly (DFM, DFMA)
- Assembly Method Optimization/Evaluation
- Dimensional Analysis
- Cost Reduction
- Metal-to-Plastic Conversion
Structural Analysis (FEA)
As plastics are being used in more demanding applications every day, one of the best tools for predicting their success is structural finite element analysis (FEA). The Madison Group uses this tool to determine part and assembly performance including the following:
- Effect of temperature on stress and displacement within a part
- Resulting deflection and stress from pressure and mechanical loads on proposed design surfaces
- Impact of forces on a part over an extended period of time (creep)
- Consequence of fiber reinforcement on material property anisotropy with resulting stress and displacement within a part
- Influence of weld lines
The full evaluation of a design before production is a crucial step in the development of any product. This will avoid costly manufacturing problems, or worse, failures during intended use.
Frequently Asked Questions
General & Process
What is included in a design review from The Madison Group?
Our design reviews are comprehensive and tailored to your project. They could include part geometry optimization, stress calculations, structural analysis (FEA), Design for Manufacturing and Assembly (DFMA), and material reviews.
At what stage of development should I request a design review?
Ideally, as early as possible. Conducting a review during the early development stages allows us to catch potential failures and manufacturing issues before you invest in expensive tooling. However, we can also assist in optimizing existing designs or solving problems in legacy parts.
How long does a typical design review take?
The timeline varies based on the complexity of the part and the depth of analysis required (e.g., whether you need a basic geometry check or a full Structural FEA). Contact us with your project details for a specific estimate. However, we understand that fast turnarounds are important for our customers and projects are generally completed within the days to weeks, rather than months timeframe.
Technical Capabilities
Can you help with metal-to-plastic conversions?
Yes. One of our core specialties is helping companies transition from metal to plastic. We analyze the structural requirements and environmental factors to ensure the plastic alternative meets or exceeds the original metal part’s performance while enabling design flexibility, reducing weight, complexity, or cost.
What is FEA, and why do I need it for my plastic part?
FEA (Finite Element Analysis) is a digital simulation tool we use to predict how a part will respond to real-world stresses like temperature changes, pressure, and mechanical loads. For plastics, this is crucial because their behavior is non-linear and changes significantly over time and temperature (creep).
Do you consider environmental factors in your reviews?
Absolutely. We evaluate how your design will hold up against chemical exposure, humidity, ultraviolet (UV) light, and temperature fluctuations to ensure long-term service life.
Manufacturing & Materials
How does a design review help with manufacturing?
We use Design for Manufacturing (DFM) principles to ensure your part is not only functional but also easy and cost-effective to produce. This includes optimizing gate placement, reducing cycle times, and identifying potential molding defects before production begins.
Will you help me choose the right material?
Yes. While material selection is a distinct service, it is a critical factor we consider in all our projects. We look beyond basic data sheets to understand how a specific polymer’s chemistry and reinforcements (such as fiber orientation) will interact with your part geometry and its intended environment to ensure long-term performance.
Business & Partnership
How do I get started with a design review?
You can reach out through our “Contact” form. Providing us with your current CAD files, performance requirements, and any known challenges will help us provide a more accurate proposal.
Can you work with my existing molding or tooling partners?
Yes. We often act as a technical advocate for our clients, working alongside tool designers and molders to ensure the final product aligns with the optimized design we’ve developed.
Inquire Today
At The Madison Group we are always ready to provide support in any of the product development stages you may be. Whether you are developing a new product, improving an existing one, or solving a problem, we have the experience needed to optimize a design for success. Contact us today and request information that will help you finalize your design faster and more effectively.
