A Plastics Engineer’s Perspective on Proper Product Development

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Goddard Technologies employs a diverse staff of engineers and product managers with a wide range of expertise. In this blog, Craig Frigon, Senior Mechanical Engineer, delves into his specialty in plastics engineering and how it’s been crucial in the product development process for both med tech and commercial clients.

Plastic is one of the most ubiquitous and versatile materials humans have created. In today’s world, almost every industry relies on plastic in one way or another. I like to describe plastics engineering as a mashup of chemical, mechanical, and industrial engineering. It is a specialized field focused on the design, development, and processing of plastic materials and is essential for creating products that meet the demands of modern industries.

What is the Versatility of Engineering Plastic Material?

Understanding plastics engineering begins with a strong knowledge of chemistry and how these long chains of molecules tangled together can make materials with such a wide range of physical properties. These materials are categorized based on unique properties such as tensile strength, impact resistance, flexibility, thermal stability, etc. A plastics engineer’s expertise ensures that the chosen material not only meets the functional requirements but also optimizes cost, manufacturability, and sustainability. Selecting a suitable material then influences everything from part design to manufacturing methods.

What is the Critical Role of a Plastic Engineer?

Plastic engineering is crucial during the prototyping phase, with 3D printing easily becoming the leading method for doing so quickly and effectively. Ideas need to be created and tested rapidly and in a manner that will ensure the prototype will represent the final product in terms of material properties, performance, and aesthetics. This iterative process is vital for validating the product’s functionality, safety, and durability, reducing market failure risk.

Even before the prototype phase, a plastic engineer thinks about how this part will be manufactured and assembled. Each type of plastic manufacturing has its own set of constraints and possibilities. Having a plastics engineer who understands the intricacies of each process will reduce the risk of excessive design iterations and manufacturing delays. From flexible extruded tubing to micro-injection molding, plastics have allowed researchers to make leaps and bounds in advancing technologies across all medical fields.

The Evolution of Engineering Plastic Material

On that note, the world of plastics is constantly evolving its technology. Innovations such as nanocomposites and biocompatible materials are enabling the development of advanced medical devices and implants. Goddard is continually pushing us to learn about the new advancements in our industries, which is precisely why I know we will find the right solutions for any problem.

A Plastic Engineer in Real-World Product Development

One project where this knowledge was needed was during the with our client, Aurie. We needed to thermally bond flexible material to a hard plastic cap. The bond was failing, and there was an effort to learn why. Through additional material research, we were able to determine that the thermal bonding temperature of the hard material was not reached by the heated die fixture. After some simple process changes to bring the hard material up to bonding temperature, the bond held successfully and performed as desired.

SharkNinja, another Goddard client, is at the forefront of household and kitchenware technology. This means they must be time-conscious when bringing a product to market. Since most of their products involve some, if not all, parts made of plastic, the products require a plastics engineer with foresight on how a part will be manufactured—even during the prototyping phase. As a plastics engineer on SharkNinja projects, I bring my expertise to the capabilities and limitations of the materials used to design the most robust and cost-effective product.

All the engineers here at Goddard have different backgrounds, education, and experience, and that variety allows us to provide our customers with the best product development services possible.

Learn more about how plastics engineers like Craig can help turn your product development idea into a reality.

About Craig:

Craig has a BS in Plastics Engineering from UMASS Lowell. He has over six years of industry plastic experience, ranging from high-volume thermoforming to prototype/DFM for 15+ injection-molded parts for a Class 1 medical device and accompanying disposables. He also has experience designing plastic injection-molded parts for consumer products such as fruit and vegetable juicers and vacuum cleaners.

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