custom plastic housing

Plastic Mold Part Design Engineering

Definition of Plastic Mold Part Design Engineering

Plastic mold part design engineering refers to the process of creating the design and specifications for plastic components that will be produced using injection molding or other similar manufacturing processes. This field involves a combination of engineering principles, material science, and practical considerations to develop effective and efficient designs for plastic parts that can be mass-produced.

Key aspects of plastic mold part design engineering include:

  1. Functional Requirements: Understanding the intended function of the plastic part and designing it to meet specific functional requirements.
  2. Material Selection: Choosing the appropriate plastic material based on factors such as strength, durability, thermal stability, and cost.
  3. Manufacturability: Ensuring that the design can be effectively and economically manufactured using plastic injection molding or other molding processes. This involves considerations such as mold complexity, tooling, and cycle time.
  4. Geometry and Tolerance: Defining the shape, dimensions, and tolerances of the part to meet both functional and manufacturing requirements.
  5. Structural Integrity: Ensuring that the design provides adequate structural support and strength to withstand the intended loads and conditions.
  6. Aesthetics: Considering the visual appearance of the part, especially if it is a consumer product, and incorporating design elements that enhance its aesthetic appeal.
  7. Assembly Considerations: Designing parts with features that facilitate efficient assembly processes, such as snap fits or interlocking components.
  8. Cost Optimization: Striving to create designs that are cost-effective in terms of material usage, manufacturing processes, and assembly.
  9. Prototyping and Testing: Developing prototypes to validate the design and ensure that it meets performance and quality standards.
  10. Environmental Considerations: Taking into account environmental factors such as recyclability and sustainability when choosing materials and designing the part.

Successful plastic mold part design engineering requires collaboration between designers, engineers, and manufacturing experts to create a design that not only meets functional and aesthetic requirements but also can be produced efficiently and cost-effectively in large quantities.Plastic Mold Part Design Engineering

Basics of Plastic Mold Part Design Engineering

Designing plastic parts for molding involves considering various factors to ensure successful manufacturing and optimal performance. Here are some basics of plastic mold part design engineering:

  1. Functional Requirements:
    • Clearly define the intended purpose and functionality of the plastic part.
    • Identify any specific performance criteria the part must meet, such as load-bearing capacity or chemical resistance.
  2. Material Selection:
    • Choose an appropriate plastic material based on mechanical properties, thermal characteristics, chemical resistance, and cost.
    • Consider factors like part lifespan, environmental conditions, and regulatory requirements when selecting materials.
  3. Part Geometry:
    • Design the part with simplicity in mind to reduce manufacturing complexity and cost.
    • Avoid sharp corners and edges that could lead to stress concentrations.
    • Ensure uniform wall thickness to prevent issues like warping and sink marks.
  4. Draft Angles:
    • Incorporate draft angles on vertical surfaces to facilitate easy ejection from the mold.
    • Draft angles reduce friction between the part and mold, improving the molding process.
  5. Wall Thickness:
    • Maintain consistent wall thickness to prevent issues like uneven cooling, warping, and sink marks.
    • Avoid extremely thin or thick sections; strive for uniformity.
  6. Ribs and Bosses:
    • Use ribs for added strength and stiffness in specific areas.
    • Design bosses (projections) carefully, considering wall thickness, draft angles, and material flow during molding.
  7. Undercuts and Side Actions:
    • Minimize undercuts to simplify mold design and reduce tooling costs.
    • Evaluate the need for side actions or sliders to create features that cannot be formed with a simple two-part mold.
  8. Gate Placement:
    • Strategically place gate locations to ensure proper material flow and minimize cosmetic issues.
    • Consider part geometry and gate types (e.g., edge gates, pin gates) for optimal results.
  9. Tolerances:
    • Define tight tolerances only where necessary to meet functional requirements.
    • Consider the manufacturing process capabilities and limitations when specifying tolerances.
  10. Moldability and Process Considerations:
    • Work closely with mold designers and manufacturing experts to ensure the part is manufacturable.
    • Consider factors like injection molding cycle time, cooling, and tooling requirements during the design phase.
  11. Prototyping and Testing:
    • Create prototypes to validate the design and identify potential issues before mass production.
    • Conduct testing to ensure the part meets performance and quality standards.
  12. Documentation:
    • Provide clear and comprehensive design documentation, including 2D drawings and 3D models, for communication with mold makers and manufacturers.

By addressing these basics, designers can create plastic parts that not only meet functional requirements but are also optimized for efficient and cost-effective manufacturing through processes like injection molding.

Design for Manufacturability

“Design for Manufacturability” (DFM) is an approach to product design that emphasizes the importance of considering the manufacturing processes during the design phase. The goal is to create products that are not only functional and aesthetically pleasing but also easy and cost-effective to produce. Here are key principles and considerations for Design for Manufacturability:

  1. Simplicity and Standardization:
    • Keep designs as simple as possible to minimize manufacturing complexity.
    • Use standardized components and materials to reduce costs and lead times.
  2. Material Selection:
    • Choose materials that are readily available and well-suited for the intended manufacturing processes.
    • Consider the environmental impact, cost, and availability of materials.
  3. Designing for Processes:
    • Understand the manufacturing processes (e.g., injection molding, machining, casting) and design parts accordingly.
    • Tailor designs to leverage the strengths of specific manufacturing techniques.
  4. Tolerance and Fits:
    • Specify tolerances that are necessary for functionality while considering the capabilities of the manufacturing processes.
    • Use appropriate fits to ensure ease of assembly and reduce the risk of errors during production.
  5. Assembly Considerations:
    • Design parts with features that facilitate efficient assembly, such as snap fits, self-locating features, and minimal fasteners.
    • Minimize the number of components to reduce assembly time and complexity.
  6. Cost Optimization:
    • Evaluate design choices in terms of material costs, processing costs, and assembly costs.
    • Consider the entire product life cycle, including maintenance and disposal costs.
  7. Design Iteration and Prototyping:
    • Incorporate feedback from manufacturing experts during the design process.
    • Prototype designs to identify and address potential manufacturing challenges early in the development cycle.
  8. Tooling and Molds:
    • Design parts that are compatible with standard tooling sizes to reduce tooling costs.
    • Minimize complex features that may require intricate molds.
  9. Scalability:
    • Ensure that the design is scalable for mass production without significant changes.
    • Consider the production volume and plan for potential variations in demand.
  10. Quality Assurance:
    • Design with quality control measures in mind to ensure consistency in manufacturing.
    • Incorporate features that make it easier to inspect and test the final product.
  11. Environmental Considerations:
    • Consider the environmental impact of the manufacturing processes and materials used.
    • Design for recyclability and sustainability where feasible.
  12. Collaboration:
    • Foster collaboration between design, engineering, and manufacturing teams to address challenges and find optimal solutions.

By adopting a Design for Manufacturability approach, companies can streamline their production processes, reduce costs, and enhance overall product quality. This proactive approach helps bridge the gap between design and manufacturing, leading to more efficient and successful product development.

We are China Mold Company, we offer a comprehensive set of integrated engineering capabilities from the development of part design, mold design, plastic mold manufacturing and low-cost assembly processes and engineered components. Our experience in product design and development, project management, design for manufacture and assembly, manufacturing transfers and product lifecycle management is built on structured business processes and extensive product and process expertise. Our commitment is to ensure that you obtain every objective of your design intent and the full benefit of SINCERE TECH’s services.Plastic molds

A Structured Development Process

At SINCERE TECH, our engineers provide technical skills in a broad range of engineering disciplines. Cross-functional teams are assigned at the beginning of the program and stay with the project into production, which ensures better designs and faster results. Our design, development, Moldmakers, and technical staff currently includes over 200 professionals with an extensive breadth of experience and offer a fresh perspective and confidence that only comes with experience.

We separate the development process into three distinct phases.

In Phase I. We develop specifications, generate concepts and fabricate working proof-of-principle prototypes. In Phase II.  We complete the design for manufacturability and fabricate multiple devices for animal or clinical trials.

In Phase III.  We procure final tooling, develop and conduct all the product and process validations, and release the product to manufacturing. We can begin this process at any phase of the development.

Product Development Experience

Our experience in Product Development – from component design and manufacture to finished devices to assembly processes – provides our customers with a full spectrum of integrated medical device development capabilities.

Traditional product development requires a structured approach from concept to design to analysis and finally into manufacturing. This process constrains the entire downstream organization until each upstream task is complete. Typical outcomes of this approach keep manufacturing engineers and outside suppliers uninvolved, risking inefficient manufacturing processes and excessive COGS.

Today, SINCERE TECH China Mold Maker provides customers with a competitive advantage by getting involved early in the product development cycle, integrating project teams and using concurrent engineering practices and supply chain management to accelerate speed-to-market.  This non-traditional product development process results in much shorter overall development timelines while ensuring the lowest possible COGS are obtained at the launch of the product.

Get your plastic mold part design service from sincere tech.