Custom plastic switch parts serve as core components for electrical connection and control, directly impacting electrical safety, operational experience, and equipment lifespan. By precisely matching plastic material properties with switch functional requirements and integrating advanced processing technologies with customized workflows, we establish a full-process solution from structural design to mass production, meeting diverse needs for switch parts in residential, industrial, and smart device applications.
Custom Plastic Switch Part

I. Core Material Properties and Application Advantages

(A) Comparison of Mainstream Material Properties

Material Type
Density (g/cm³)
Temperature Range (℃)
Flammability Rating (UL94)
Insulation Resistance (Ω)
Core Advantages
Typical Certifications
Acrylonitrile Butadiene Styrene (ABS)
1.05
-20~80
V-0 (1.6mm)
≥10¹²
Easy molding, cost-effective, high design flexibility
IEC 60695-2-11 Glow Wire Test Certification
Polycarbonate (PC)
1.20
-40~130
V-2
≥10¹³
High transparency, impact resistance, dimensional stability
UL 746C Material Certification
Polybutylene Terephthalate (PBT)
1.31
-40~150
V-0 (0.8mm)
≥10¹⁴
Low hygroscopicity, chemical resistance, high wear resistance
IEC 60243 Dielectric Strength Certification
Nylon 66 (PA66)
1.14
-40~180
V-2
≥10¹³
Self-lubrication, fatigue resistance, high strength
RoHS Environmental Certification
PC/ABS Alloy
1.15
-30~120
V-0
≥10¹³
Balanced high strength and toughness
REACH SVHC Compliance

(B) Driving Forces of Customization Requirements

1. Safety Performance Requirements

  • Flammability rating must meet UL94 V-0 (0.8–3.0mm thickness), no sustained combustion in glow wire test (850℃).
  • Insulation resistance ≥10¹²Ω (500V DC), dielectric strength ≥25kV/mm to prevent electric leakage.

2. Functional Performance Requirements

  • Key life ≥50,000 presses (GB 16915.1 standard), contact resistance ≤50mΩ with stability error ≤5%.
  • Waterproof switch parts must achieve IP65 rating (water jet protection), dustproof rating IP5X (complete dust resistance).

3. Environmental Adaptability Requirements

  • Weather resistance: QUV aging test for 1000 hours, color difference ΔE ≤3, strength retention ≥80%.
  • Low-temperature resistance: Key force change ≤10% at -40℃, suitable for cold northern regions.

II. Analysis of Four Core Processing Technologies

(A) Injection Molding: High-Precision Structural Processing

  • Technical Advantages
    • Supports thin-wall design (wall thickness 0.8–2.0mm), enabling ultra-thin switch panels (thickness ≤3mm).
    • Multi-cavity molds (32–64 cavities per mold) with production efficiency of 1500–3000 pieces/hour, compatible with Mainstream specifications like 86-type and 118-type switches.
  • Process Parameters
    • Injection pressure 100–160MPa, mold temperature 60–90℃, cooling time 10–20 seconds.
    • Shrinkage control: ABS 0.4%–0.7%, PBT 1.0%–1.5%, ensuring mounting hole accuracy ±0.1mm.

(B) Surface Treatment Technologies

Process Type
Typical Application Scenarios
Technical Highlights
Flame Retardant Coating
Socket housings, high-temperature switches
Nano-scale flame retardant coating, oxygen index ≥28%, thickness 50–100μm
Insulation Spraying
Insulation isolation for conductive parts
Epoxy resin coating, insulation resistance increased 10x, thickness 20–30μm
Laser Engraving
Key characters, indicator markings
Laser precision ±0.05mm, supports 0.5mm ultra-fine fonts, friction resistance ≥1000 cycles
Electroplating
High-end switch decorative parts
Chrome plating thickness 8–12μm, salt spray test ≥500 hours, glossiness ≥90GU

(C) Secondary Processing: Functional Enhancement

  • Structural Reinforcement
    • Metal insert molding (e.g., copper terminals), pull-out force ≥50N to ensure wiring reliability.
    • Snap-fit structure design, disassembly force controlled at 8–15N to prevent accidental detachment.
  • Touch Optimization
    • Silicone key overmolding, press force controlled at 15–25N, rebound force error ≤±2N.
    • Sandblasting treatment (roughness Ra 1.6–3.2μm), anti-slip performance improved by 30%.

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

  • Process Advantages
    • Rapid validation of irregular structures (e.g., curved switch panels, smart sensor housings), samples delivered in 48 hours.
    • Nylon 12 material with 80MPa strength for functional testing (e.g., waterproof sealing tests).
  • Application Scenarios
    • Custom smart switch housings (order quantity ≤500 pieces), delivery cycle reduced by 40%.
    • Reverse engineering for obsolete parts (3D scanning error ≤0.08mm).

III. Full-Process Customization Solutions

(A) Design and Material Engineering

1. Multi-Dimensional Design Support

  • Structural Optimization
    • ANSYS simulation analyzes key stress distribution to ensure deformation ≤0.3mm after 50,000 presses.
    • Anti-misoperation design: Key travel controlled at 3–4mm, edge chamfer R≥2mm to reduce misoperation probability.
  • Functional Customization
    • Smart switches: Pre-installed sensor slots (accuracy ±0.05mm) for Wi-Fi module and LED indicator integration.
    • Explosion-proof switches: PBT + 30%GF material, shell strength increased by 40%, compliant with IEC 60079 explosion-proof standard.

2. Precise Material Selection

  • Residential Switches: ABS + flame retardant (cost-effective, meets daily fire safety needs).
  • Industrial Control Switches: PBT material (120℃ long-term resistance, oil pollution resistance).
  • Smart Switches: PC/ABS alloy (high transparency for uniform LED backlighting).

3. Pre-Processing Technology

  • Raw material drying: PBT moisture content controlled ≤0.03% to avoid post-molding hydrolysis cracking.
  • Color matching: Pantone color accuracy ΔE ≤0.8, supports personalized colors like matte white and champagne gold.

(B) Production and Quality Control

1. Flexible Manufacturing Capability

  • Rapid Prototyping
    • 3D printed samples delivered in 24 hours, aluminum mold development cycle 10–15 days (steel mold 30–40 days).
    • Supports minimum order quantity of 100 pieces for small-batch customization.
  • Mass Production
    • Automated production lines with KUKA robots, daily capacity 50,000 pieces (86-type switch panels).
    • Intelligent inspection: Machine vision system detects defects like short shots and flash, accuracy ≥99.5%.

2. Comprehensive Testing System

  • Electrical Performance
    • Dielectric withstand test: 2000V AC for 1 minute without breakdown, leakage current ≤0.5mA.
    • Contact resistance: Dynamic test for 50,000 cycles, resistance fluctuation ≤10% (GB/T 14048.5 compliant).
  • Environmental Performance
    • Thermal cycling: -40℃~70℃ for 50 cycles, dimensional change rate ≤0.2%.
    • Chemical resistance: 5% sodium chloride solution immersion for 24 hours, no corrosion or discoloration.
  • Certification Support: Provides CCC, CE, UL, and other certification reports for global market access.

IV. Multi-Scenario Application Solutions

(A) Residential Switch Applications

  • Wall Switch Panels: ABS material + electroplated decorative strips, surface hardness ≥2H, supports 86/118/120-type specifications, mounting hole pitch accuracy ±0.5mm.
  • Smart Socket Housings: PC/ABS alloy + laser-engraved characters, transmittance ≥85%, compatible with USB-C/Lightning interfaces, fire rating V-0.

(B) Industrial Control Applications

  • Explosion-Proof Switch Parts: PBT + glass fiber material, explosion mark Ex d IIB T6, suitable for high-risk environments like petroleum and chemical industries.
  • Machine Tool Operation Panels: PA66 material + silicone keys, oil resistance (48-hour immersion without swelling), key life ≥100,000 cycles.

(C) Smart Device Applications

  • IoT Switch Modules: Ultra-thin PC housing (1.5mm thickness), supports NFC sensing area design, antenna signal attenuation ≤5dB.
  • New Energy Vehicle Switches: Low-temperature resistant TPU material (-40℃ impact strength ≥25kJ/m²), waterproof rating IP67, adapted to vehicle vibration (10–2000Hz frequency).

(D) Special Scenario Applications

  • Medical Device Switches: ABS + antibacterial treatment (bacteriostasis rate ≥99%), smooth surface for easy cleaning, compliant with ISO 13485 medical standard.
  • Aviation Switch Parts: Titanium-reinforced PA material, tensile strength ≥100MPa, passed RTCA DO-160G vibration test.

V. Technology Selection Guide

Requirement Type
Preferred Technology
Material Choice
Core Indicators
Delivery Cycle
R&D Validation & Small Batches
3D Printing + Injection Molding
ABS/PC
Rapid iteration, irregular structures
Prototype in 3 days, batch in 15 days
High Safety & Temperature Resistance
Injection Molding + PBT
PBT
Flammability V-0, 150℃ temperature resistance
Prototype in 7 days, batch in 25 days
Large-Scale Standardized Production
High-Speed Injection Molding + ABS
ABS
Low cost, high production efficiency
Prototype in 5 days, batch in 20 days
Smart Integration Needs
Secondary Processing + PC/ABS
PC/ABS Alloy
Transmittance ≥80%, sensor compatibility
Prototype in 7 days, batch in 30 days
Custom plastic switch parts achieve full-category coverage from basic residential switches to high-end industrial explosion-proof components through deep integration of material properties, processing technologies, and application scenarios. Whether meeting the safety requirements of household electricity or the strict standards of industrial control, our end-to-end technical capabilities ensure each customized solution precisely meets benchmarks for flame retardancy, insulation, and durability. For custom solutions using ABS/PBT/PC materials, certification processes, or production capacity data, contact us for professional support from design development to mass production.

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