Design and development of plastic products

Development of plastic products: from concept to finished solution

Replast designs plastic products with a view to future production, operational loads, materials and mass-production requirements. We help you navigate the journey from an idea or technical brief to a well-thought-out design that can be manufactured consistently, cost-effectively and to a predictable standard of quality.
The result of our work is a well-thought-out plastic product design, ready for prototyping, tooling or production launch.

What is involved in the design and engineering of plastic products

The comprehensive development of a plastic product involves analysing the requirements, designing the product, selecting the material, 3D modelling and preparing for production. Each stage affects the strength, appearance, usability and cost of the finished product.

The stages of designing a plastic product in Replast

Analysis of the concept, functional requirements and scope of application of the product

At the outset, we determine the product’s intended use, its operating conditions, the expected loads, and the requirements regarding dimensions, shape, stiffness, weight and appearance. This enables us to establish the technical basis for the subsequent design work.

Development of a technical concept for a plastic component

At this stage, the idea is transformed into a practical design. We consider the product’s shape, functional elements, joints, fastenings, stiffeners, wall thickness and other parameters that affect reliability and manufacturability.

Industrial design and ergonomics of the product

If a product comes into contact with the user or is intended to form part of a finished product, factors such as usability, proportions, appearance and intuitive operation become crucial. The design is developed to combine aesthetics, functionality and the ability to be reliably manufactured from plastic.

3D modelling of plastic products

A 3D model allows you to assess the shape, design and compatibility of components even before production begins. Using the model, you can check the geometry, make changes and prepare data for prototyping, mould making or other production equipment.

Selection of polymeric material for specific operating conditions

The material is selected based on strength, flexibility, temperature resistance, chemical resistance, appearance, weight and budget. Choosing the right plastic helps to avoid deformation, premature wear and excessive production costs.

Preparation for prototyping or production

Once the design has been approved, the necessary data is prepared for the production of a prototype, the manufacture of tooling, or the launch of production. Where necessary, the design is adapted to reduce costs, simplify assembly or improve quality consistency.

Engineering supervision of works

We support the product during the implementation phase, helping to make technical adjustments, analyse the first prototypes and adapt the design to real-world production conditions.

Which products is this service suitable for?

The design and engineering of plastic products are required for new products, technical components, parts, packaging, profiles and components to be manufactured from polymer materials. This service is suitable both for developing a product from scratch and for improving an existing design.

Housings, covers and technical plastic components
Packaging components and accessories
Plastic profiles and extruded products
Components for industry, construction and consumer goods

The benefits of having custom plastic parts designed by Replast

Replast’s key strength lies in its practical approach to design. We do not design plastic products in isolation from the manufacturing process, but take into account the material, technology, equipment, production volume and future production costs.