Digital plastic parts, with their outstanding lightweight characteristics, precise moldability, aesthetic plasticity, and functionality, have become indispensable components in digital products such as smartphones, tablets, laptops, and wearable devices. By deeply integrating material properties with the functional and aesthetic design requirements of digital products, customized processing technologies offer a comprehensive solution from conceptual design to mass production.
Custom Digital Plastic Parts: Full-Process Solutions

I. Core Material Properties and Application Advantages

(A) Comparison of Mainstream Material Properties

Material Type
Density (g/cm³)
Temperature Range (°C)
Core Advantages
Typical Certifications
Polycarbonate (PC)
1.20–1.22
-40 to 130
High light transmittance, excellent impact resistance, dimensional stability
UL746C Material Certification
Acrylonitrile Butadiene Styrene (ABS)
1.03–1.07
-20 to 80
Easy moldability, high toughness, superior surface treatment performance
UL94 V-0 Flame Retardant Certification
Polymethyl Methacrylate (PMMA)
1.18–1.20
-40 to 90
Exceptional optical properties, high surface hardness
ISO 7823 Optical Standard Certification
Polybutylene Terephthalate (PBT)
1.31–1.53
-40 to 150
Low hygroscopicity, chemical corrosion resistance, excellent electrical insulation
IEC 60243 Dielectric Strength Certification
Liquid Silicone Rubber (LSR)
1.12–1.25
-60 to 200
Soft touch, water and dust resistance, aging resistance
FDA Food Contact Certification

(B) Driving Forces of Customization Core Requirements

  1. Aesthetics and Texture:
    • Surface roughness Ra ≤ 0.4μm to achieve a mirror – like finish, meeting high – end product demands.
    • Support various surface treatment processes, such as anodizing, electroplating, and In – Mold Decoration (IMD), with Pantone color matching accuracy ΔE ≤ 0.8.
  1. Functionality and Performance:
    • Structural parts require high strength and toughness; for example, smartphone frames should withstand a squeezing force of ≥ 100N without deformation.
    • Heat dissipation components demand good thermal conductivity, with a thermal conductivity coefficient ≥ 0.5W/(m·K).
  1. Thinness and Precision:
    • Minimum thickness can reach 0.3mm, satisfying the design requirements of ultra – thin digital products.
    • Dimensional accuracy is controlled within ±0.03mm to ensure precise assembly of components.

II. Analysis of Four Core Processing Technologies

(A) Injection Molding: High-Precision Structural Part Processing

  • Technical Advantages:
    • Capable of one – step molding of complex structures, such as clasps, threads, and blind holes.
    • Multi – cavity molds (32–64 cavities per mold) with a production efficiency of 2,000–5,000 pieces per hour, suitable for digital parts weighing 1–100g.
  • Process Parameters:
    • Injection pressure 100–160MPa, mold temperature 40–80°C, cooling time 8–15 seconds.
    • Shrinkage control: 0.5%–0.8% for PC, 0.4%–0.7% for ABS, ensuring dimensional accuracy.

(B) Two – Color Injection Molding: Integration of Function and Appearance

Process Type
Typical Application Scenarios
Technical Advantages
Two – Color Co – injection
Smartphone buttons, headphone casings
One – step molding of two colors or materials, enhancing product visual effects and functionality
Soft – Hard Overmolding
Smartwatch straps, tablet cases
Composite molding of soft and hard materials, balancing comfort and durability
  • Technical Highlights:
    • Bonding strength between two – color materials ≥ 12MPa, passing 5,000 bending tests without delamination.
    • Precise control of the injection sequence and position of two materials to achieve complex functional designs.

(C) 3D Printing: Rapid Prototyping and Small – Batch Customization

  • Process Advantages:
    • Quickly fabricate complex curved surfaces and hollow structures, such as headphone cavities and smartphone stands.
    • Use materials like photopolymer resin and nylon, with a printing accuracy of up to ±0.1mm.
  • Application Scenarios:
    • Rapidly verify designs during new product development, with samples delivered within 3 days.
    • Customize small – batch personalized parts to meet niche market demands.

(D) In – Mold Decoration (IMD): High – End Aesthetic Customization

  • Technical Features:
    • Integrate printing, molding, and decoration within the mold, with a surface hardness ≥ 3H.
    • Support various patterns and textures, such as carbon fiber and leather patterns.
    • Excellent wear and scratch resistance, passing 1,000 friction tests without significant scratches.
  • Typical Applications:
    • Back covers of high – end smartphones, tablet panels.
    • Smart speaker casings, enhancing product texture and brand recognition.

III. Full – Process Customization Solutions

(A) Design and Material Engineering

  1. Multi – Dimensional Design Support:
    • Structural Design: Optimize component stress distribution using finite element analysis to ensure reliability in daily use.
    • Functional Customization:
      • Heat dissipation hole design: Optimize the shape and layout of holes through CFD fluid simulation, increasing heat dissipation efficiency by 30%.
      • Waterproof and dustproof structures: Achieve IP68 protection level, suitable for outdoor use.
  1. Precise Material Selection:
    • Smartphone casings: Select PC/ABS alloys with excellent impact resistance, passing the 1.5m drop test without breakage.
    • Optical lenses: Use PMMA material with a light transmittance ≥ 92%, meeting optical performance requirements.
  1. Pre – Processing Technology:
    • Raw material drying: Control the moisture content of PC material ≤ 0.02% to prevent bubbles and silver streaks after molding.
    • Surface modification: Add anti – fingerprint coatings to reduce fingerprint residue and maintain a clean appearance.

(B) Production and Quality Control

  1. Flexible Manufacturing Capability:
    • Rapid Prototyping: 3D printed samples delivered within 24 hours, aluminum mold development cycle 7–10 days (steel mold 20–30 days).
    • Mass Production:
      • High – speed injection lines: Equipped with automated robotic arms, with a daily production capacity of 30,000 pieces per machine.
      • Intelligent production lines: Achieve fully automated processes from injection molding, inspection to packaging, with a yield rate ≥ 99%.
  1. Comprehensive Testing System:
    • Physical Properties:
      • Impact test: Withstand a 2J energy impact without damage at -20°C.
      • Abrasion test: Pass the Taber abrasion test with a wear amount ≤ 5mg.
    • Optical Properties:
      • Light transmittance detection: Use a spectrophotometer to ensure compliance with product standards.
      • Haze detection: Haze value ≤ 1% to ensure clear visual effects.
    • Environmental Certifications: Provide RoHS, REACH, and other test reports to ensure product environmental compliance.

IV. Multi – Field Application Scenarios

(A) Smartphones

  • Smartphone Casings: PC/ABS casings processed by IMD, combining aesthetics and durability with excellent anti – fingerprint performance.
  • Smartphone Buttons: Two – color injection molded silicone buttons, offering a comfortable touch and a service life of ≥ 100,000 presses.

(B) Wearable Devices

  • Smartwatch Straps: Liquid silicone rubber straps, skin – friendly and comfortable, with a waterproof performance reaching IP68 level.
  • Headphone Casings: Two – color injection molded PC/TPU casings, stylish and impact – resistant.

(C) Tablets and Laptops

  • Tablet Cases: Soft – hard overmolded cases, providing comprehensive protection and a good hand feel.
  • Laptop Heat Dissipation Grilles: Hollow – designed PBT heat dissipation grilles, effectively improving heat dissipation efficiency and ensuring stable laptop performance.

(D) Smart Home Control Devices

  • Smart Remote Control Casings: ABS casings with spray painting treatment, smooth surface and comfortable grip.
  • Smart Camera Casings: PC casings with waterproof and dustproof functions, adaptable to various usage environments.

V. Technology Selection Guide

Requirement Type
Preferred Technology
Weight Range
Core Indicators
Delivery Cycle
Rapid Prototyping and Small – Batch Personalized Customization
3D Printing
1–50g
Complex structures, fast delivery
Prototype in 1–3 days, batch in 7–15 days
Medium – to – Large – Batch Standardized Production
Injection Molding + IMD
5–100g
High precision, high – quality appearance
Prototype in 5–7 days, batch in 15–25 days
Functionally and Aesthetically Composite Parts
Two – Color Injection Molding
10–80g
Multi – material integration, one – step molding
Prototype in 7–10 days, batch in 20–30 days
Custom digital plastic parts achieve full – category coverage from tiny components to large casings through the deep integration of material properties, processing technologies, and digital product requirements. Whether it is the ultimate pursuit of aesthetic texture or the strict requirements for functionality and performance, the full – process technical capabilities ensure that each customized solution precisely meets the standards in appearance, function, and quality. For customized solutions of PC, ABS, and other materials, certification testing processes, or production capacity data, please feel free to contact us. We provide professional support from design and development to mass production.

Recommended Reading