Practical tips for reducing part costs
Reducing injection molding design costs is critical to achieving cost-effective manufacturing without compromising part quality.
Practical tips for reducing part costs
Reducing injection molding design costs is critical to achieving cost-effective manufacturing without compromising part quality.
1. Maintain consistent and appropriate wall thickness throughout the part to prevent sink marks and optimize material use.
2. Choose standard mold bases and components as much as possible to reduce mold costs.
3. Avoid or minimize complex undercuts that require additional mold operations. Simplify part geometry to reduce mold complexity and cost.
4. Apply draft to all vertical surfaces to ensure easy release of parts and reduce wear on mold components and tooling finish surfaces.
5. Carefully select gate type and gate location to minimize material waste and reduce appearance defects. For high-volume parts, consider using a hot runner.
6. Select cost-effective materials that meet part performance requirements. Consider using recycled or environmentally friendly materials to reduce costs and environmental impact.
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7. Combine multiple parts into one design to reduce assembly and labor costs, which does not overly amplify tooling problems.
8. Strategically use ribs and gussets to reinforce areas where extra strength is needed, allowing for thinner walls overall.
9. Specify appropriate tolerances and surface finishes to meet functional requirements without unnecessary precision or cost.
10. Iteratively prototype and test designs to identify and resolve potential problems early, thereby reducing costly design changes in later stages.
11. If feasible, design multiple parts that can be molded together in a single tool, thereby reducing cycle time and tooling costs. To save costs, the cavity should be balanced and the limited flexibility of the tool must be accepted.
12. Design optimized cycle times by considering factors such as cool runer design, part geometry, and material flow.
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