09 Mar 3 Design factors to remember when molding
3 Design factors to remember when molding
What are the 3 design factors to remember when molding?
Read it below:
Because although injection molding can be used for a wide range of products, there are a number of design rules that you have to adhere to. If you don’t do this? Then you risk product defects. And we want to avoid that.
Number 1: Moldflow
A lot can go wrong when the liquid plastic is sprayed into the mold. Is the wall of a product too thick? Then sink marks can occur when the product is not given enough time to solidify.
Another problem can arise when a design does not allow every part of a product to cool down simultaneously. This increases the risk of weak parts in a product, which allows the product to bend in these places.
Thirdly, when a design requires the plastic to be injected into different streams – such as a steering wheel – this can lead to flow lines at the point where the flows of plastic meet.
All these defects arise from a suboptimal plastic flow in the mold. Analytical software for moldflow can simulate such a flow even before a mold is created. In this way we can spot potential defects and weak points and prevent them by adjusting the mold design.
Number 2. Product ejection
In order to produce as efficiently and cost-effectively as possible, the aim is to make it easy for every part of a product to be thrown out of the mold.
In short, this means that the sides of a product are not designed in 90 degrees, but at an angle that facilitates the ejection of a product. When the product has to be ejected at a 90 degree angle, there is continuous friction. This is undesirable. The ideal angle depends on two things: the depth of the relevant part of the mold and the function that the product should have.
Finally: the assembly phase. When a product consists of many parts, this phase can be very costly and time consuming. Smart product designers are thinking many steps ahead about how to design a product in a way that reduces the number of assembly steps. This is also called the ‘design for assembly’ approach.
This can be done in several ways: for example, by using less parts. But an alternative is to take into account properties that facilitate connection of loose parts. Think of pins and holes that you can easily click together.
As you now see, there are many design factors that make a product so cost-efficient and risk-free. Do you have a good product idea? Don’t forget to include the 3 design factors when molding! You can also read more on wikipedia, among others
A good injection molder also takes this into account and is always one step ahead of risks. At Orange Plastics, our experienced engineers will help you to develop the perfect design.