How to Save Money When Buying Precision Mold Development

Injection Moulding Design Tips: 9 Strategies for Cost Reduction

Self-Mating Components

Are you designing a snap case for medical devices or two interlocking halves of a portable radio? Instead of creating two separate mating parts, consider making a single universal part. Redesign the snaps so both halves can fit together in either direction. This approach requires only one mold, resulting in reduced production costs upfront. You can also mold double the quantity of one part rather than half the amounts of two different parts.

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Modifications to Molds

Removing metal from an existing metal mold is generally easier than adding metal back. This can be a challenge, especially in rapid injection molding situations. Understanding this concept, known as 'metal safe' design, is essential. Injection-molded parts often go through several iterations before reaching a final design. Rather than purchasing a new mold for every update, strategic planning allows for the same mold to be reused multiple times. Start with a simple part design, mold as many pieces as necessary, and then re-machine the mold to incorporate additional features or an enlarged version of the part. This methodology isn't exact but can greatly reduce tooling development costs when applied correctly.

DFM Analysis for Mouldability

Every quote for an injection-molded component at Protolabs comes with a complimentary design for manufacturability (DFM) analysis. This analysis pinpoints potential issues or opportunities for improvement in your design. Factors such as insufficient draft angles, un-machinable features, or impractical geometries can be identified, allowing for necessary adjustments before final approval.

Utilizing Multi-Cavity and Family Moulds

Are you in need of a higher volume of parts? You can achieve this using aluminum tooling with two-, four-, or eight-cavity molds, depending on the size and geometry of your parts, which can effectively lower your unit price, though this will increase your tooling costs. If you have a family of components that fit together, it's possible to mold them simultaneously instead of spending resources on individual molds—provided they meet certain criteria such as being made from the same plastic and being roughly the same size.

Additionally, consider using living hinges to connect parts. This technique is especially effective for molding clamshell-style containers that would typically require a pin-type assembly to open and close. Just ensure that you use a flexible and durable material such as polypropylene (PP).

Considerations of Part Size

Pay attention to the dimensions of your parts. In molding terminology, it's crucial to assess part size and whether it will fit comfortably in the mold, including allowances for sprues, runners, ejector pins, and other necessary elements. Protolabs has a maximum size for injection molding of 480mm x 751mm and a depth of up to 101mm from the parting line. However, larger parts necessitate larger molds, impacting both mold and part costs.

8 Effective Strategies to Minimize Your Injection Mold Expenses

Cutting down on manufacturing costs is a goal for every business. Generally, for large-scale production, injection molding is less expensive compared to 3D printing or CNC machining, with added flexibility for limited runs and prototypes. Making informed design decisions can significantly lower injection mold expenses. Many design enhancements lead to reduced costs while simultaneously improving product quality and speed of production.

To achieve a balance between spending less and producing high-quality products, understanding the capabilities and limitations of both the injection molding machinery and the materials used is crucial. Here are eight strategies to consider:

1. Conduct a Mold Flow Analysis Prior to Using an Injection Molding Machine

Identifying design issues after using the injection molding machine can lead to enormous costs. A mold flow analysis employs specialized software to simulate the molding process and assess designs with the specific plastic formulation planned for use. This digital modeling helps to predict key product characteristics, such as potential air bubbles and shear stress, enabling businesses to refine their designs before their molds or products incur any substantial expenses.

2. Plan for Mold Modifications to Reduce Injection Molding Costs

Mold developers find it simpler to remove metal than to add it back. As such, a metal-safe design plan focuses on removing material but never incorporating it back into the mold. This strategy holds particular importance since molds often need several alterations before achieving a final design. For instance, consider a common prototyping method:

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• Start with a basic design.
• Once the initial design is approved, modify the mold by removing metal to incorporate more features or expand the size.

By avoiding the need to buy a new mold for every design iteration, businesses can enjoy substantial savings and hasten their design processes.

3. Design Self-Mating Parts to Lower Injection Mold Costs

In some cases, a single piece may serve as both components of a product. For example, a container designed with a top and bottom that snap into place could be developed as one part that connects from either side. Instead of crafting two distinct molds, you can produce both halves from a single mold, making it more efficient and cost-effective to manufacture double the quantity of the same part.

4. Simplify or Eliminate Unnecessary Features

Including logos, textures, and other elements may enhance products and help with branding. However, additional features can lead to extra costs associated with injection molding. Some cosmetic details are essential due to regulatory requirements, but sensible design practices can help minimize expenses. For example, using straightforward fonts such as Arial or Verdana, with sizes no smaller than 20 pt., and limiting cut depths to .015 inches, can help control costs.

5. Reduce or Remove Cosmetic Elements

Just as with unnecessary features, cosmetic details can enhance the product's aesthetics and branding, but each additional feature can raise costs. Organizations need to weigh the benefits against these extra expenses.

• High-quality finishes require manual polishing.
• Larger areas will cost more to polish than smaller areas.

6. Explore Overmolding Options to Save on Manual Labor

Simpler designs inherently cost less than intricate ones. However, incorporating additional features may increase costs initially but can prove more economical over the long term. Consider the need to add gaskets for sealing; investing in overmolding that incorporates this feature may incur a higher upfront cost but can prevent expenses associated with labor for manual assembly later on. In such cases, spending more on a complex injection mold can still be the more cost-effective choice throughout the production cycle.

7. Investigate Multi-Cavity Molds to Reduce Labor

In some instances, separate components are produced independently and assembled later. Nonetheless, producing these components as a single cohesive piece often makes more sense. This approach can also enhance the durability of the final product. For instance, you might fuse two parts of a container together with a molded hinge. This technique reduces or entirely eliminates the labor involved in manually fastening the components together afterward.

8. Select the Best Injection Mold Service Plan

Choosing the right service option dramatically impacts costs and production efficiency. For instance, a prototyping service plan may have lower overall costs but higher costs per part produced. These plans could also impose fees for extras like inspection reports. Conversely, while production-ready injection molding plans incur a higher initial cost, they typically lower the cost per part produced and encompass additional benefits such as longer storage options and greater flexibility.

Maximizing Benefits from Injection Molding

A streamlined design generally results in reduced costs, but businesses should also consider features that enhance product quality or reduce manual labor. Pairing with a reliable partner can aid clients in achieving the right balance.

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