Manufacture of plastic components

The production of plastic components includes both parts made from polyester-glass laminates and thermoplastic components used in tanks, catch basins, safety pallets and cabinets for dosing systems. At STOLAM, we work with materials selected for specific applications, taking into account their mechanical properties, chemical resistance and operating conditions. Depending on the project, we use glass-fibre-reinforced plastics and thermoplastics such as PE, PP and PVC.

Every component is manufactured with due regard to its geometry, function and technical requirements, and the entire process involves design, the preparation of moulds or models, the production of the component and its subsequent finishing.

Experience that translates into production

We have been operating continuously since 1980, specialising in the production of plastic components using hand-lay-up technology. Over the years, we have developed a practical approach. We are expanding our scope of activity to include areas related to thermoplastics and 3D design. We can work at both the concept stage and on the production of finished components. We provide technical support throughout the entire process.

The basic stages of plastics production

The production of plastic components begins with the design and analysis of the technical specifications. In the case of polyester-glass laminate moulds, the process starts with a model on which the mould is built. The surface of the model is prepared, coated with a release agent, and then with a special moulding gelcoat.

Once this has cured, successive layers of reinforcement are applied, consisting of glass mat impregnated with vinyl ester resins and low-shrinkage polyester resins. For thermoplastic components, production involves:

• material selection,
• preparation of panels,
• moulding,
• welding,
• welding
• and assembly of fittings.

Regardless of the technology, proper material preparation, dimensional control and tailoring the entire process to the intended use of the finished product are of key importance.

What components can be made from plastics?

Plastics can be used to produce both small parts and large structures. In our production, these are primarily:

• bodywork components for buses and trams,
• spare parts for interior fittings,
• bumpers,
• wheel arches,
• lamp covers
• and other GRP/GFK components.

In the field of thermoplastics, we manufacture industrial tanks, spill containment trays, safety pallets and cabinets for dosing systems. Plastics are also widely used in the production of: 

• pipes,
• containers,
• covers,
• technical components
• and components used in industrial, chemical, food and laboratory installations.

What processing technologies are used in the manufacture of plastic components and other plastic products?

We use various technologies in the production of plastic components, depending on the type of material and the intended use of the part. For laminates, both hand-lay-up and spray-up methods are used. At STOLAM, we use the hand-lay-up method, as it allows us to accurately reproduce details, maintain dimensional stability and tailor the process to the individual requirements of the project.

The following processes are used in the processing of thermoplastics:

• bending,
• welding,
• hot-air welding,
• and thermoforming.

For models and moulds, we use CNC milling of materials such as MDF, wood or polystyrene. The surfaces are then filled, sanded and finished with varnish to achieve the required technical and aesthetic quality.

Quality control in the manufacture of plastic products

Quality control covers both the production stages and the assessment of the finished component. In the case of laminates, the thickness and saturation of the material, curing conditions and surface condition are checked. Once the component has been manufactured, its dimensional accuracy, finish quality, surface condition and workmanship are assessed.

In the production of thermoplastic tanks, the inspection covers the correctness of joints and welds, dimensional conformity with the design, surface quality and leak testing. The tanks are completely filled with water for 24 hours, which allows, amongst other things, for the verification of any defects, condensation on welds and joints, and the leak-tightness of the entire structure. Each finished component must be ready for further assembly and use without the need for additional adjustments.

Glass-fibre-reinforced plastics

Glass fibre-reinforced plastics are among the most widely used materials in industry. Glass fibres are characterised by high mechanical strength, low weight and resistance to UV radiation, water, moisture and many external factors. The addition of glass fibre to thermosetting resins results in a material with greater stiffness and durability. 

After the cross-linking process, the material becomes rigid, insoluble and resistant to high temperatures and chemicals. Composites of this type are used in the automotive, shipbuilding, mechanical engineering, energy, refrigeration and public transport industries.

Plastics processing

The processing of plastics depends on their type and application. Thermoplastics are lightweight, easy to process and can be remelted and moulded repeatedly without losing their properties. They can be processed by bending, welding, fusing or thermoforming. When it comes to polyester-glass laminates, processing requires experience and the right technological conditions. Once the component has been produced, it is sanded, the reinforcements are fitted, and the surface is further finished. Depending on the design, the components may be supplemented with steel or aluminium parts, painted and prepared for transport.

3D modelling, manufacturing and painting in a single process

A 3D model allows us to check the geometry, component fit and assembly method before work begins. Based on this, we manufacture parts from GRP, GFK or thermoplastics, and then prepare them for further use – including surface finishing.

From design to finished component

Following the modelling stage, we move on to production, machining and painting. Each component is tailored to the technical specifications and operating conditions, whilst the paint finish protects the surface from external factors and prepares the part for assembly.

Glass-fibre-reinforced plastic laminates

GRP/GFK polyester-glass laminates are produced by combining polyester resin with a glass fibre mat. This results in a composite with an excellent strength-to-weight ratio. The outer visual layer is finished with a gelcoat selected for its UV, thermal and chemical resistance.

A suitably selected gelcoat protects the surface even in harsh conditions, such as humidity, seawater or contact with aggressive chemicals. Laminates enable the production of lightweight and durable components with complex shapes, maintaining dimensional stability and a long service life. For this reason, they are widely used in transport, mechanical engineering, the maritime industry and the energy sector.

Are you looking for a manufacturer of plastic components? Contact us – we will select the right production technology and prepare a solution tailored to your project!