Design Smarter, Mold Better: How Product Architecture Affects Mold Efficiency
Introduction
In injection molding, product design directly impacts mold complexity, cost, and longevity. A well-optimized part design reduces mold maintenance, improves cycle time, and ensures consistent quality. Here’s how to align product architecture with mold optimization.
Key Strategies
Wall Thickness Uniformity
Avoid abrupt thickness changes to prevent sink marks, warping, or uneven cooling.
Ideal range: 1–3mm (varies by material). Use ribs for structural support instead of thickening walls.
Draft Angles & Undercuts
Add draft angles (1–3°) to ease demolding and reduce wear on cores/cavities.
Minimize undercuts with sliders or lifters to simplify mold structure.
Parting Line & Gate Location
Design parting lines along flat surfaces to reduce flash and finishing costs.
Position gates at thick sections to ensure smooth material flow (e.g., edge gates for flat parts).
Consolidate Components
Combine multiple parts into a single molded piece (e.g., snap-fits, living hinges) to reduce assembly and mold complexity.
Case Study
A client redesigned an automotive panel with uniform wall thickness and added 2° draft angles, reducing mold wear by 30% and cycle time by 15%.
Conclusion
Collaborate early with mold engineers to implement Design for Manufacturability (DFM) principles. Small design tweaks can yield significant cost savings.
