These are the steps involved in making electronics components, as well as the recommended technologies and materials used to make them.

Types of parts commonly manufactured for electronics 

The types of parts you’ll need for electronics will of course depend on the product. However, the following are the parts we often see our customers producing.

• Plastic housings. Plastic injection moulding is often used to produce slim and lightweight housings for various electronic devices, providing durability and aesthetics.
• Metal housings. Aluminium and steel enclosures serve as protective shells for electronic equipment such as industrial control systems, server racks and scientific instruments, shielding internal components from external elements.
• Printed circuit board (PCB) mounting brackets. These brackets hold PCBs securely in place in electronics such as medical devices and industrial sensors, ensuring stability and proper alignment of electronic components.
• Battery housings. Engineers precision-engineer battery cases to hold rechargeable and non-rechargeable batteries in various electronic applications, such as medical equipment, remote monitoring devices, and instrumentation, providing convenient power solutions.
• Hinges and mechanical components. Used in electronics such as field equipment, aerospace instrumentation and industrial machinery, these components ensure reliable movement and functionality of critical parts.
• Prototypes. Manufacturers often use various forms of 3D printing to produce prototypes for a wide range of electronic applications, including custom sensors, research equipment, and specialized instrumentation. This approach enables rapid iteration and testing of new designs.

Manufacturing methods for electronics

Manufacturing methods for electronic parts include a range of techniques from injection moulding to 3D printing to sheet metal fabrication. The right process for your application should be chosen based on the final application for your part.

• Injection moulding. Manufacturers use injection molding to produce plastic components like housings, enclosures, and keypads. They inject molten plastic into a mold cavity, then cool it to form the desired part. It’s efficient for high volume production and offers precise detail.
• CNC machining. CNC machines precisely remove material from a solid block, creating parts with tight tolerances and complex geometries. CNC machining allows you to produce precise and intricate metal parts for electronics, such as aluminium enclosures with customised cut-outs for circuit boards and connectors.
• Die casting. Die casting produces metal parts with intricate shapes, such as aluminum or zinc alloy housings. Manufacturers inject molten metal into a mold, allow it to cool, and then remove it, resulting in highly detailed and durable components. It is a good choice for producing complex electronic components such as heat sinks, or lightweight yet durable aluminium alloy housings with intricate designs and fine details, such as those used in smartphones or tablets.
• Sheet metal fabrication. Sheet metal fabrication involves cutting, bending and assembling thin sheets of metal such as aluminium or steel to create various components such as housings, brackets and chassis. This process is particularly suitable for parts that require strength, durability and electromagnetic shielding, often found in devices such as computers, amplifiers and servers.
• 3D printing. 3D printing enables the creation of intricate, custom-designed components, layer by layer. It’s useful for rapid prototyping and low-volume production of parts such as housings, unique connectors, specialised brackets or prototypes of end products.

Selecting materials for parts for electronics

When selecting a material, you should consider several factors related to the nature of the electronics for which your part is intended. These factors will vary depending on the application, but here are a few important – if not universal – ones. 

• Functionality. Ensure the material meets the functional requirements of the part, such as electrical conductivity, insulation, heat resistance, or mechanical strength.
• Durability. Consider the material’s ability to withstand wear and tear, impacts, and environmental conditions relevant to the device’s use.
• Weight. Choose a material that balances the need for strength with the desire for lightweight components, especially for portable devices.
• Cost. Material cost can significantly impact production expenses, so balance material performance with budget constraints.
• Manufacturability. Assess whether the chosen material is compatible with the manufacturing processes needed to produce the part efficiently.
• Heat dissipation. Determine whether the material dissipates heat effectively, which is crucial for components exposed to heat-generating electronics.
• Dimensional stability. Choose materials that maintain their shape and dimensions under varying temperature and humidity conditions.
• Aesthetics. The material’s appearance and finish should align with the device’s design and user expectations.

The exact material you need will also depend on the intended application of the part. However, we often see our customers using the following to produce parts for electronics.

• Plastics. PC, ABS and PP are widely used for 3D printed or injection moulded housings, enclosures and various internal components due to their light weight, versatility and ease of moulding. In addition, PC, ABS and PP offer various properties such as impact resistance, heat resistance and chemical resistance. Find out more about these and other materials commonly used in injection moulding.
• Aluminium. Manufacturers favor aluminum for its lightweight yet strong properties, using it for housings, heat sinks, and structural components in laptops, smartphones, and audio equipment. It offers excellent heat dissipation and a sleek appearance.
• Steel. Manufacturers use steel, particularly stainless steel, for its durability and corrosion resistance in electronic components such as structural elements, fasteners, and hinges.
• Silicone. Manufacturers value silicone rubber for its flexibility, heat resistance, and electrical insulation properties. It seals, absorbs shocks, and provides protective coatings for cables and connectors in electronics.
• Carbon fibre. Manufacturers use carbon fiber composites for their exceptional strength-to-weight ratio and resistance to electromagnetic interference (EMI). These materials reinforce structures and provide EMI shielding in high-end or heavy-duty electronics.

Surface finishes for parts for electronics

Surface treatments can provide parts with improved aesthetics, durability and functionality. Here are five commonly used finishes, along with examples of how they can be applied in electronic applications.

• Anodising. Anodized aluminum surfaces with enhanced corrosion resistance and an attractive finish are used in electronics, aerospace components, and medical instruments, where durability and appearance are critical.
• Electroplating. Electroplated coatings such as gold or chrome enhance the conductivity and appearance of connectors, switches and buttons in a variety of electronic systems, including telecommunications equipment and automotive electronics.
• Painting and powder coating. These finishes provide customised colours and protective coatings for plastic and metal components in electronic applications such as industrial control panels and outdoor electronics, ensuring both functionality and aesthetics.
• Brushed and polished finishes. Brush or polish stainless steel and aluminium components to achieve a premium appearance and enhance the overall appeal of electronic devices, such as high-end audio equipment, laboratory instruments, and precision measurement tools.

Sourcing Simplified – Start Your Next Project With PROTO MFG

Are you looking for a reputable partner for your parts fabrication and machining projects? Look no further. At PROTO MFG, we specialize in CNC machining and related technologies, including sheet metal fabrication, rapid prototyping, etc. Whether it is a project with a simple design or parts with complex geometries, do not hesitate to contact us today!