6 Do’s and Don’ts from the Experts
When designing a product, it’s easy to create something that fits all requirements for the product's intent without any thought about the manufacturing process. Many times, it might not be clear what manufacturing process will be used to produce the final product.
At Tenere, we understand the complications that come with adjusting a design to complement the injection molding manufacturing process. Our Design for Manufacturability (DFM) engineers have decades of experience helping customers make modifications to their designs to ensure their product is manufacturable, cost-conscious, can meet geometric tolerances, and works with the chosen material without compromising the integrity and functionality of the product.
*engineering tip: .step files are the best choice when sharing design files
We have put together 6 design tips to help engineers with designing for injection molding.
Tip 1: Do not design a part with non-uniform nominal wall thickness
- Varying wall thickness creates uneven fill throughout the cavity
- Thinner sections will cool faster than thicker areas causing highly stressed areas where distortion and warping will occur
- It is recommended to core out the thick areas to create uniform walls, which will reduce cycle time and plastic usage and improve part cosmetics
- Depending on the type of material being used, nominal wall thickness should not vary more than 15%
Tip 2: Do identify possible sink areas and design them out
- Sink areas are likely to occur at intersections of a rib and nominal wall where proper design guidelines are not followed
- Rule of thumb: Ribs should be a maximum of 70% of nominal wall, but 60% is preferred