DFM (Design for Manufacturing)
DFM principles and methodologies entail a rigorous examination of all relevant parameters, optimizing manufacturing efficiency in strict accordance with the validated project technical specifications. The DFM process prevents design flaws and reduces the incidence of defects, ensuring that all project criteria are aligned with the initial objectives. Implementing DFM minimizes design-to-manufacturing iterations and delays, thereby accelerating the product development cycle.
Project Technical Specifications Optimize Manufacturing Efficiency. Prevent design flaws and reduce defect rates. Accelerate product development cycle.By simulating with professional mold flow analysis software, comprehensive insights are provided into material filling and solidification, predicting flow dynamics pathways, cooling duration, and stress concentration points. This analysis helps foresee potential defects, allowing for modifications to the mold design and refinement of processing parameters before manufacturing. Consequently, it reduces risks associated with new mold development, enhances manufacturing productivity, and conserves time and costs throughout the development cycle.
Reduce the risks associated with new mold development. Improve manufacturing efficiency. Save time and money.The Services of DFM
Geometric Configuration
Optimize plastic part geometries for efficiency in machining and assembly. Eliminate undercuts for seamless mold release. Design with fillets and chamfers to replace sharp corners and edges, thereby mitigating stress concentrations and reduce mold abrasion. Thoughtfully integrate reinforcing ribbing and structural supports to enhance the mechanical strength and rigidity of the components.
Improve processing and assembly efficiency. Enhances mechanical strength and rigidity of components.Steel Material
In selecting the appropriate mold steel based on the plastic material properties and the expected mold life, it is imperative to ensure the steel’s wear resistance and hardness. The steel’s ability to resist thermal fatigue, along with its robust tolerance to the thermal stresses associated with the molding process, is vital for preventing cracks and extending the operational life of the mold.
Extend the service life of the mold. Ensures wear resistance and hardness of steel.Parting Line
An optimal parting line (P/L) design achieves the product’s aesthetic integrity and functional requirements while also considering the economics of mold fabrication and maintenance. The P/L should not intersect with the part surfaces to maintain the product’s visual elegance. It should be designed to optimize the mold structure, thereby reducing manufacturing costs and the production timeline. The P/L design should ensure proper demolding to prevent any warping or damage during the injection molding process.
Reduce manufacturing costs and production time. Prevent any warping or damage during the injection molding process.Gating Design
Gate system design requires assessment of various critical parameters, including product dimension and functionality, product appearance, material properties, mold structure, and production costs. Gate type options include edge gate, side gate, sub-gate, pinpoint gate and more. Define the appropriate gate type in accordance with the product’s dimensions and geometry. The gate location is critical to ensure a uniform and adequate filling of molten plastic into the mold cavities. And the gate should not be positioned on the cosmetic or functional surfaces of products. The gate size should correspond to the wall thickness and volume of parts to prevent incomplete filling. Good flow plastics are suited to a small gate size, whereas poor flow plastic may require a large gate size. Furthermore, the gate system also needs to consider factors such as injection pressure, injection speed, cycle time, and automation operations among others.
Draft Angle Design
Incorporating an optimized draft angle ensures the components to be released from the mold smoothly. This design feature mitigates the risk of part damage, including scoring or marring, thus safeguarding the structural robustness and cosmetic finish of the molded parts.
Reduced risk of component damage, including scratches or abrasions.