Introduction
Sometimes, rapidly changing market trends and a change of mind on the part of the customer may necessitate minor changes in the geometry of injection molded products after the first design has been finalized and is in the production line. At this point, making an entirely new mold is not a feasible option and can also reduce cost-effectiveness and time required for the entire project.
If the manufacturer does not have strategies to accommodate minor design variations during the process without having to re-execute the entire process, he cannot survive in the ever changing market. Besides, there are instances when the first design may have loopholes only to be discovered once the production is started. In order to avoid extra costs and time covering those flaws, manufacturers need to rely on some advanced techniques that offer design flexibility without negatively impacting the final fit of the product. Hence, flexibility in design can enhance the efficiency of the process itself and allow for variations in design for the better quality and geometry of the final product.
The Impact of Design Variation on the Process and the Product
What apparently seems to be a minute variation in design during the production phase, can actually have far reaching impact on the injection molding process, final fit of the component, and its performance especially when you don’t have proper strategy and tools in place for design flexibility.
Variations of even a few millimeters in geometry can significantly impact the entire process and the injection molded components. For example :
- Even a tiny change in gate location can impact the fashion in which the molten matter fills the mold. This can raise issues like bubble formation, the appearance of weld marks, and uneven filling when done without precise calculation and proper tools.
- Even a 5% change in wall thickness can cause uneven cooling with thicker parts cooling down later than the thinner ones. This may result in warping.
- Warping caused by a minor variation in the design of cooling channels can highly impact the dimensions and final fit of the product.
- Uneven and extended cooling times due to variation in design can change the cycle time of the process.
- When the holes are misaligned, the final product can have compromised strength causing breakage in the longer run.
- Above all, misplaced holes can lead to the issues of assembly when the parts are to be connected to each other.
In other words, the injection molded process is highly sensitive to even the minutest variation attempts in design and when it is done without having the capacity for design flexibility, the entire process and the end product can be compromised.
How to Improve Design Flexibility During Injection Molding
Keeping in view the above mentioned serious issues arising due to design variations during the process of production, it is highly imperative to have a well thought out strategy backed by proper software and tools to allow for design flexibility and accommodate minor changes. This is important because of three reasons:
Market trends keep changing continuously and what might be a practicable geometry might have become obsolete or less preferable by the time the production of a product ends. Hence, in-process variations might be required to keep up with the changing trends.
- The initially approved design might show imperfections as the product is actually put in the production line. This means you need to introduce changes to perfect these flaws and for that, your process should have flexibility because changing the mold altogether can be very costly and time-consuming
- Sometimes, the customers might not be satisfied with the initially produced samples and may demand slight variations in design. The manufacturers who can ensure such flexibility with design are in better position to win the trust of the customers.
- Besides, with design flexibility options in hand, quick prototyping is possible and you can test different designs before finalizing one.
Here are some of the best possible strategies to enhance design flexibility and hence improve the design flexibility as well as the injection molding process:
· CAD Design Software
A CAD design software can help cover the loopholes in the design or make it more efficient with highly precise and calculated changes in design. It is one of the most relied upon CNC machining technique. There are several options in this regard. For example, the software like AutoCAD, Fusion 360, and SolidWorks can come in handy for meticulous alterations in design without changing the mold.
· Go for Modular Designing Strategy
Another way to allow for design variations is to adopt a modular designing strategy which allows for reconfiguring the design without having the need to redesign the product altogether.
· Adopting the DFM (Design for Manufacturability) Approach.
This is a common approach adopted by the suppliers of injection molded products today. It necessitates that the product design is optimized specifically for the process of injection molding so that when required it can be altered for betterment without redesigning completely. This encompasses the elements like material flow, tolerance, and geometry.
· Using Simulation Tools
This is one of the most advanced and tested-for-accuracy techniques to ensure the highest accuracy when there is a need for variation. The simulation software like Moldflow and others can help you accurately access how the material flows and cools down in a mold. This can help you test different models without overspending.
· Using Material with Better Flexibility
Going for the materials which offer higher optimization for injection molding can reduce the chances of deformities with minor variations. For example, latest polymers and composite material have better flexibility.
Our Commitment to Adopting the Latest Technologies in Enhancing Design Flexibility
We, at art-tangent are always committed to lead the market amidst the changing landscape of injection molding world. We ensure that the latest technological advancements like insert molding, gas assisted injection molding, and overmolding etc. are given way after repeated testing for betterment in the process and making it more adaptable.
Conclusion
In conclusion, enhancing design flexibility in injection molding is not merely a strategic advantage but a necessity in today’s dynamic market environment. The ability to accommodate minor design variations without the need for costly mold changes can significantly improve efficiency and product quality. By leveraging advanced CAD software, modular design approaches, and simulation tools, manufacturers can mitigate risks associated with design changes and optimize the injection molding process. Embracing these technologies not only ensures adaptability to evolving market trends but also fosters customer trust by delivering products that meet exacting standards. As industry leaders, our commitment to integrating cutting-edge technologies underscores our dedication to continuous improvement and customer satisfaction in the injection molding industry.
References
https://en.wikipedia.org/wiki/Computer-aided_design
https://en.wikipedia.org/wiki/Moldflow
https://art-tangent.com/capability/
https://art-tangent.com/product-category/plastic-products
https://medium.com/@sogaworksofficial/what-is-insert-molding-a-comprehensive-guide-e8572ea02077
