Injection molding design is the cornerstone of any program run. When a design has been thoroughly vetted, it means that a manufacturing program can last multiple cycles with proper mold maintenance.
This becomes even more achievable when design for manufacturability practices are incorporated and engineering teams from customers and manufacturers work together to create a solution that works not just once, but every time.
Agape Plastics highlights the importance of utilizing design for manufacturability in injection molding design.
Why DFM Matters in Injection Molding Design
Design for manufacturability is one of the best ways to take a design, ensure manufacturability, and speed up a production process rather than working through constant design changes and the fears of tooling changes. Truly, there are four main considerations as to why DFM matters in injection molding design.
When DFM is applied to injection molding design, it not only catches potential defects, but it greatly reduces any defects that would otherwise go undetected. This is because DFM practices catch geometries favorable to defects like sink.
Tooling and production costs are ultimately lowered when teams utilize a DFM approach to their design operation.
The time-to-market is greatly sped up as potential issues are identified before any manufacturing actually begins. This bypasses multiple phases of trial-and-error from prototyping and mold rework.
Lastly, DFM properly accounts for optimized material usage so injections are engineered exactly to the necessary amount of molten plastic, saving costs and reducing waste.
How to Obtain Successful Results
There are common traits found in all injection molding design considerations that no matter the project, application, material, or industry, a program can adhere to. When these parameters are closely followed, DFM support becomes much more attainable and easier for engineering teams to achieve.
- Teams should keep wall thickness as uniform as possible to avoid multiple defects including warp, sink, residual shrink, and differential cooling.
- Incorporate draft angles into vertical walls for parts to eject cleanly from the mold rather than scraping or sticking and causing surface or internal defects.
- If wall thickness needs to change in specific spots, utilize ribs and bosses, and size them properly to add necessary stiffness rather than using more materials.
- Eliminate or minimize undercuts and complex features to rid side actions and extra tooling costs.
Practical Impact
Design for manufacturability targeted at injection molding design achieves a couple of major targets that any production run aims to hit from a manufacturing standpoint. When DFM practices are incorporated, it greatly reduces debug time, scrap material, and improves a first-pass yield. In addition, it keeps molds simple which ultimately extends tool life and minimizes maintenance pains.
Partner with Agape Plastics for More Tips on Injection Molding Design
Agape Plastics knows just how important injection molding design is to the lifeblood of a program. When the design for your project is ironed out and finalized, along with tooling, it means multiple production runs are possible and your components can repeatedly be manufactured for several cycles.
Design capabilities have come a long way since we opened our doors in 1973 and in our Grand Rapids, Michigan, facility, we see some of the most exciting designs create essential components every day. Agape Plastics performs work for OEMs and Tier 1 supplier programs throughout multiple industries, and our engineering team works with our customers to advise design considerations to ensure design for manufacturability is achieved.
When your project is ready for a review, the team at Agape is here for you. Contact us today to set up an initial consultation on your specs and let’s take your project from CAD file to a physical component.