Design & Production Process
The plastic injection molding of PFA or FEP resins do not follow the traditional guidelines used for more common thermoplastics such as polyethylene, polypropylene, nylon or even acrylics. Highly engineered resins like PFA and FEP have very unique properties that can make them ideal candidates for more challenging applications. However, significant know-how is required to engineer a part design that is compliant with FEP/PFA resins. Tooling must also be designed with adequate flow paths, appropriate shrink factors, specialized heating and cooling capabilities and constructed of materials that are resistant to corrosive gases. Molding process development is also an important factor in assuring the dimensional consistency and physical properties of the finished part. Savillex will bring its more than forty years of FEP/PFA injection molding knowledge and expertise on your behalf to every new project so that we can exceed your expectations. We look forward to partnering with you on your next development.
Design & Production Process
1. Customer Request for Quotation
The process begins with the customer submitting as much relevant information as possible about the part to be molded. Savillex provides an on-line quotation request form that will help guide the customer though the list of important criteria that gives Savillex engineers a thorough understanding of the customer’s requirements. Even if the customer is only in the conceptual stages of product development, a 2D drawing or 3D solid model is the best way to convey design intent. Other important design features, functional requirements, or critical dimensions should also be highlighted.
2. Initial Design Review
Savillex engineers will review the information and contact the customer within two business days from date submitted. In conversations with the customer, Savillex engineers will try to get a more in-depth understanding of the part’s application specifics and where design constraints may exist. If Savillex engineers see potential opportunities to improve the moldability of the part through product design enhancements, those will be discussed with the customer. Various grades of resin will also be discussed to assist the customer in selecting the material that best fits the application. Depending on part design, additional topics for discussion may involve the need for secondary operations on the part after molding. After a thorough review with the customer and a decision on the acceptability of any design enhancements that have been recommended, the Savillex engineer will take that information and proceed to a budgetary quotation.
3. Budgetary Quote
The budgetary quotation that Savillex provides is a step in the process that allows the customer to see preliminary costs for both parts and tooling. These costs will be a very close approximation to the final but offer the ability for the customer to adjust design specifics, resin or tooling concept to evaluate various costing and lead time scenarios. This step can be very helpful for the customer in determining the best course to follow without having to finalize all design documentation. Savillex will provide the budgetary quotation within three business days after the initial design review has been completed with the customer.
4. Finalized Design and Quotation
Based on the budgetary quotation, the customer has determined that the project is viable and meets their criteria to move forward. The customer prepares all final design documentation, models, specifications, tolerances, etc. and forwards it to Savillex for final review. Upon acceptance Savillex will provide a final quotation to the customer within two business days.
5. Purchase Order and Tooling Design/Construction
Upon receipt of the purchase order from the customer, Savillex will begin with the tooling design. All tool design and construction is performed internally at Savillex so that the maximum benefit of our expertise can be utilized. Regular progress updates are provided to the customer throughout the tooling construction phase. The tooling construction timeframe varies with the complexity of every project but generally tooling will be completed within 6-12 weeks from the receipt of the purchase order.
6. Molding Process Development
When the tooling has been completed and transferred to the molding operations, Savillex engineers will develop a sampling plan based on key dimensional attributes that were reviewed with the customer. Molding process development will begin within one week after the tool has been completed. Molding experimentation will ensue until the key part attributes can be consistently reproduced. At this point the molding process is locked down, documented and stored. Part samples are run for “first article inspection.” A comprehensive report is completed and provided to the customer with sample parts for their own analysis.
7. Project Approval
The project is complete when approval is given by the customer. Savillex prepares a documented in-process quality inspection plan to be employed when the parts are released by the customer for full production. Each release for shipment will have agreed upon quality inspection data provided. Parts will be shipped in accordance with instructions provided with each purchase order.