Electrical plastic parts, valued for their excellent insulation, lightweight nature, flame retardancy, and design flexibility, serve as core components in various fields, including home appliances, 3C products, smart home devices, and industrial electrical equipment. Through precise matching of material properties with electrical functional requirements, customized processing technologies provide end – to – end solutions from structural design to mass production.
Custom Electrical Plastic Parts

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
Acrylonitrile Butadiene Styrene (ABS)
1.03–1.07
-20 to 80
High strength, high toughness, easy molding
UL94 V-0 Flame Retardant Certification
Polycarbonate (PC)
1.20–1.22
-40 to 130
High light transmittance, impact resistance, dimensional stability
UL746C Material Certification
Polyphenylene Oxide (PPO)
1.06–1.07
-40 to 155
Excellent insulation, chemical corrosion resistance
UL94 V-1 Flame Retardant Certification
Polybutylene Terephthalate (PBT)
1.31–1.53
-40 to 150
Low hygroscopicity, high wear resistance, arc resistance
IEC 60243 Dielectric Strength Certification
Nylon (PA)
1.12–1.15
-40 to 180
Self-lubrication, fatigue resistance, high temperature resistance
ISO 1873 Mechanical Property Certification

(B) Driving Forces of Customization Core Requirements

  1. Electrical Safety:
    • Insulation resistance ≥ 10¹²Ω (test voltage 500V), dielectric strength ≥ 20kV/mm.
    • Flame retardancy grade must reach UL94 V-0 (1.6mm thickness) or UL94 5VA (strict industrial standard).
  1. Environmental Adaptability:
    • Temperature resistance: Home appliance casings must pass the -20°C ~ 70°C thermal cycle test (no cracking after 50 cycles).
    • Weather resistance: Outdoor electrical parts need UV aging resistance (color difference ΔE ≤ 3 after QUV-A 1000 hours irradiation).
  1. Functional Integration:
    • Snap-fit structures should withstand a pulling force of ≥ 50N (no failure after 1000 opening and closing tests).
    • Heat dissipation components with surface roughness Ra ≤ 1.6μm to ensure heat transfer efficiency.

II. Analysis of Four Core Processing Technologies

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

  • Technical Advantages:
    • Dimension accuracy ±0.05mm, supporting insert molding (positioning accuracy of metal inserts ±0.1mm).
    • Multi-cavity molds (64 – 128 cavities per mold), production efficiency of 3000 – 8000 pieces per hour, suitable for 5 – 200g parts.
  • Process Parameters:
    • Injection pressure 120 – 180MPa, mold temperature 60 – 100°C, cooling time 12 – 25 seconds.
    • Shrinkage control: 0.4% – 0.7% for ABS, 1.2% – 1.8% for PBT, ensuring assembly tolerance ≤ 0.03mm.

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

Process Type
Typical Application Scenarios
Technical Advantages
Two-Color Co-injection
Buttons of smart devices, switch panels
One-step molding of parts with different colors/materials, eliminating secondary assembly
Overmolding (Soft-Hard Combination)
Handle grips, shock-absorbing pads
Composite of soft rubber (TPU) and hard plastic (PC) to enhance ergonomic experience
  • Technical Highlights:
    • Bonding strength at the interface of two-color materials ≥ 15MPa, passing 1000 bending tests without delamination.
    • Multi-component injection molding machines support simultaneous molding of 4 materials to meet complex functional requirements.

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

  • Process Advantages:
    • Direct manufacturing of hollow heat dissipation structures and special-shaped snap-fits, with a minimum detail size of 0.3mm.
    • Nylon 12CF (carbon fiber reinforced) material with a strength of 180MPa, suitable for high-strength prototypes.
  • Application Scenarios:
    • Rapid verification of structural designs during new product R&D (samples delivered in 3 days).
    • Customized parts for small batches (order quantity ≤ 500 pieces), shortening the delivery cycle by 60%.

(D) In-Mold Decoration (IMD): Integration of Appearance and Function

  • Technical Features:
    • Integration of film printing, molding, and decoration within the mold, with surface hardness ≥ 3H.
    • Supports texture designs (brushed, leather patterns) and anti-scratch coatings (withstand 1000 friction cycles without scratches).
  • Typical Applications:
    • High-end home appliance panels (reducing fingerprint residue by 80%).
    • Smart device casings (electromagnetic shielding efficiency ≥ 50dB).

III. Full-Process Customization Solutions

(A) Design and Material Engineering

  1. Multi-Dimensional Design Support:
    • Structural Optimization: Analyze the position of weld lines through Moldflow simulation to avoid electrical weak points.
    • Functional Customization:
      • Heat dissipation grilles: Optimize the opening ratio to 40%, reducing air resistance by 25% (verified by CFD fluid simulation).
      • Waterproof components: Adopt IP67 – level sealing structures, passing the 2kPa pressure test without leakage.
  1. Precise Material Selection:
    • Casings of small home appliances: Select UL94 V-0 grade ABS, which does not ignite during the glow wire test (850°C).
    • Components of high-voltage electrical appliances: Use PPO material with a volume resistivity ≥ 10¹⁶Ω·cm, meeting the GB/T 1410 insulation standard.
  1. Pre-Processing Technology:
    • Raw material drying: Control the moisture content of PA material ≤ 0.1% to avoid molding bubble defects.
    • Modification treatment: Add antistatic agents (surface resistance ≤ 10⁹Ω) for 3C product parts to prevent static adsorption.

(B) Production and Quality Control

  1. Flexible Manufacturing Capability:
    • Rapid Prototyping: 3D printed samples delivered in 48 hours, aluminum mold development cycle of 10 – 15 days (steel mold 30 – 45 days).
    • Mass Production:
      • High-speed injection lines: Equipped with Fanuc robots, with a daily production capacity of 50,000 pieces per machine (64-cavity mold).
      • Automated production lines: Achieve fully unmanned processes from injection molding, assembly to inspection, with a yield rate ≥ 99.2%.
  1. Comprehensive Testing System:
    • Electrical Properties:
      • Dielectric strength test: Withstand 25kV/mm voltage for 1 minute without breakdown.
      • Insulation resistance: Tested at 500V DC, with a resistance value ≥ 10¹³Ω.
    • Mechanical Properties:
      • Impact test: Withstand a 2J energy impact without cracking at -20°C (ISO 179 standard).
      • Fatigue test: Button life ≥ 100,000 presses, with a stroke change ≤ 0.1mm.
    • Certification Support: Provide international certification test reports such as UL, CE, and RoHS to ensure compliance with global market regulations.

IV. Multi-Field Application Scenarios

(A) Home Appliances

  • Refrigerator drawers: Made of PBT + 30%GF material, resistant to low temperatures (-30°C) and impact, with a load-bearing capacity of 15kg without deformation.
  • Air conditioner casings: PC/ABS alloy material, with a UV resistance level of 4, without fading after 3 years of outdoor exposure (GB/T 16422.3).

(B) 3C Products

  • Mobile phone middle frames: Carbon fiber reinforced nylon material, with a bending strength of 240MPa, and a drop test (1.5m) pass rate ≥ 98%.
  • Laptop heat dissipation grilles: IMD-processed parts with a 55% hollow rate, improving heat dissipation efficiency by 18%, and surface hardness of 4H.

(C) Industrial Electrical Equipment

  • Insulating parts of high-voltage switches: PPO material encapsulated with epoxy resin, with an arc resistance ≥ 180 seconds (ASTM D495 test).
  • Servo motor protective covers: UL94 5VA grade PA66, with a Glow Wire Flammability Index (GWFI) of 960°C.

(D) Smart Home

  • Smart door lock casings: Two-color injection molded PC + TPU, with a fingerprint recognition area wear resistance level of 5 (ISO 1518-2 standard).
  • Sensor protective covers: Waterproof IP68 grade PBT, without corrosion after 96 hours of salt spray test.

V. Technology Selection Guide

Requirement Type
Preferred Technology
Weight Range
Core Indicators
Delivery Cycle
R&D Verification and Small Batches
3D Printing + Injection Molding
1 – 200g
Rapid iteration, complex structures
Prototype in 3 days, batch in 15 days
Medium-Large Batch Standardization
Injection Molding + IMD
5 – 500g
High precision, decorative appearance
Prototype in 7 days, batch in 20 days
Functionally Composite Parts
Two-Color Injection Molding
10 – 300g
Multi-material integration, one-step molding
Prototype in 10 days, batch in 25 days
Custom electrical plastic parts achieve full-category coverage from 1g precision connectors to 500g large casings through the deep integration of material properties, processing technologies, and electrical functions. Whether meeting the durability requirements of home appliances or the strict safety standards of industrial electrical equipment, end-to-end technical capabilities ensure that each customized solution precisely meets the requirements for electrical performance, mechanical strength, and environmental adaptability.
For customized solutions of ABS/PC/PPO and other materials, certification testing processes, or production capacity data, please feel free to contact us. We will provide professional support from design and development to mass production.

Recommended Reading