Design for manufacturing through injection moulding involves a lot of factors that need attention. Manufacturing requires producing the product accurately and consistently on a large scale, still, it may need to produce specific features or parts requiring extra efforts from the toolmakers. Designing for manufacturing is to remove all the possible obstacles in present and keeping a scope that if something comes in future will be solvable so the following are the guidelines that ensure your design for manufacturing is unerring and the injection mould is successful.
1. KIS keep it simple – Design should be simple and functional. Try to simplify the complexity in design. Don’t make it unnecessarily complex. Simple lines, curves and shapes will make the design looks fashionable and pleasing.
2. Using standards – When designing a product, keep the ‘’off the shelf standard’’ components in mind to make it more affordable and efficient. Try not to specify the odd-sized screws and hard-to-source materials. People want maintainability, user-friendly simple design. It enhances the life of the design and avoids any situation that leads to the need for a redesign.
3. Design for Ease of Fabrication – Let not make it a challenge for toolmaker. Part of the product is to create a design that is appealing to the consumers and easier to manufacture.
4. No thin walls or anything that can deform during the cooling of your mould. It requires a long time to cool off which will likely result in costly deformation, leading to the need for a redesign.
5. Avoid Undercuts – One of the most important design element is to think about where the parting lines (Borderline in which direction changes) needs to be. Avoid bulge that hindered mould when it is opened.
6. Threads – If possible, try to avoid threads in your design. They will check the design. For example where the parting lines must go and increase the change of rejects (Defective parts).
7. Radii – The small intricate parts will increase the production costs and also the chances of rejections. Try to aim for the maximum possible radius with no compromise on the design, while designing the corners or other features that require radii.
8. Design parts that align itself with the final product – If a part is a component to larger design, make sure it aligned with the final product. During construction, if any parts, if bend or tangle it will arise the need to reconsider the design.
9. Efficient joining and fastening options – A good design will have methods of fastening without the need for screws or glue.
10. Design components that easy to assemble – Designing part should be so easy enough so that a child could construct the final product. It should be crystal clear how the part fits into the overall design.
Designing for an appealing product that is both functional and can be produced easily can be a challenge, but one of the most important parts of the design process. Presently plastic injection moulding is the best method of mass production.