Pushing material, technology innovations for better plastic parts

Plastic plays a key role in the production of electronic devices and equipment. As it does not conduct electricity, it is the safe material to use for insulation, housings, circuit boards and PCB hardware. Yet, certain advancements in technology have imbued plastic with electrical properties, extending its application to shielding electronic components. This versatility, in addition to the significant weight reduction and miniaturization offered, underscores plastic's importance in electronics and efforts to find better methods to extract it from end-of-life devices for recycling.

Engineering plastic, which is widely used in the electronics industry, has a huge market. In a report from Market Data Forecast, its value will reach $100 billion by the end of 2021 and increase at 8.3 percent CAGR to 2026. By the end of the period, the market will be in the scale of $135 billion.

The world's biggest production base for plastic parts, China is ensuring output for use in electronic devices is made of engineering plastic or thermoplastic. This material, unlike insoluble and nonmelting thermosets, is recyclable.

In addition, domestic manufacturers have gradually shifted focus to midrange and high-end plastic parts for various applications in recent years. To enhance competitiveness, they continue to invest in R&D, aiming to come up with their own modified plastic, plastic alloy and compounded plastic materials. This is to meet specific performance requirements in their key market, the electronics industry, and automotive, medical, communications, agricultural and aviation applications.

Modified or compounded plastic on the market has additives or fillers, which may be glass, carbon or aramid fiber. The last is better known as Kevlar. Ceramic, chalk, glass microspheres and talcum are also used. In fillers, which are introduced to reduce friction and wear, the choices include graphite, polyethylene, molybdenum sulphide and PTFE.

Plastic alloy is the resultant material from a compound of two or more polymers. PC/ABS, PBT, PET, PE, ASA or SMA, ABS/nylon, PPE/PS, PET/PMMA or polysulfone, PBT/ABS and PBT/PET/elastomer are some of the available plastic blends worldwide.

One Chinese company, Suzhou Hongxi, has developed plastic alloy parts, which have a 77 to 80 Shore D hardness, 100 to 150 percent elongation, 0.5 to 1 percent retraction rate and up to 150 C operating temperature. These patented products are shock-, acid- and alkali-resistant.

In manufacturing processes, suppliers of plastic parts in China have adopted ultrasonic plasticization injection molding and microlamination technologies to complement their injection molding and extrusion know-how. This is ensure high quality and precision in micro parts.

Steady market growth

In spite of the COVID-19 pandemic, the plastic industry in China realized higher profits in 2020, according to the Ministry of Industry and Information Technology. The total reached about $18.87 billion, up 18.4 percent YoY. Volume, however, went down to 76.03 million tons or by 6.5 percent.

In 2021 and 2022, production is expected to recover and post a 10 percent increase, according to AskCI.

Some companies are already planning to their expansion, anticipating demand resurgence. Sunonline Precision Industry Ltd is looking to double its output before the end of 2021 and through 2022. It has new factories in Shenzhen and India, and a recently completed one in Vietnam to have started mass manufacturing in July 2021.

There are more than a thousand manufacturers of plastic parts in China, including foreign-invested operations. Some domestic companies also produce metal parts. Few new players are expected to join this highly competitive market in coming years.

The top six provinces accounting for over half of China's output for this category are Zhejiang, Guangdong, Henan, Hubei, Jiangsu and Sichuan. Zhejiang is the biggest production hub, churning out nearly 15 percent of the country's total volume from factories in Wenzhou, Yueqing and Ningbo.

For the majority of Chinese manufacturers, the major export markets are Southeast Asia, North America and Europe.

Thermoplastic parts

PPS, nylon, PC and PP parts dominate the range in China. There are also PET, PBT, PCT, PTT, nylon 6, nylon 66, nylon 6T, LCP, PVC and PMMA products.

For connectors used in low-frequency applications, nylon and PC parts are commonly available, while high-frequency connector parts are made of glass fiber-reinforced nylon or PBT, PPS or LCP.

As this is a customization-driven category, manufacturers make sure any specifications can be met with an assurance of high quality and short lead time.

Companies obtain materials from domestic providers, but also accommodate requests for foreign sources.

Since 2020, material and labor costs have increased, forcing many suppliers to mark up their prices by 5 percent. Product quotes may stabilize in 2022 along with input costs.

Injection-molded POM part

This injection-molded part from Dongguan HLC Metal Parts Ltd, the HLCD-0616-2PP, is made of POM and meets IATF 16949 requirements.

The minimum order is 2,000 pieces for delivery within 15 days.

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Custom plastic part

Available in custom sizes, the YS-87 from Ningbo Yombo Rubber & Plastic Products Co. Ltd can be made using ABS, PP, PE, PVC, TPE, TPU, PS or PTFE. Color options include white, black, red and blue.

An order of at least 1,000 sets is required. Lead time is 15 days.

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ABS computer mouse outer shell

This XHL-IPC008 computer mouse shell from Sunonline Precision Industry Ltd is made of 100 percent ABS and has custom cutouts. Plastic parts for instruments, cases, covers and buttons are also available.

The minimum order is 2,000 pieces for delivery within five days.

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Plastic part for motor fans

This XTL-0947 plastic part for motor fans is made of PC, PVC or PMMA processed using high-pressure injection molding. It can be plated, screen-printed, painted, polished, gilded or laser-engraved.

The 1,000-piece minimum order requirement has a lead time of 10 days.

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