An important way to minimize problems in injection molding is to create accurate 2D and 3D computer aided engineering part files. Using this technique is significant, because it provides the best control over design factors such as the following:
- Minimizing shrinkage, sinking and deformation
- Defining parting lines
- Providing sufficient draft angles for proper ejection
- Gate locations
These design factors are important for maintaining the manufacturability of the parts to be injection molded. Using the established design parameters in the 2D and 3D computer generated part files, the next step is to create a mold design with the proper mold actions, gate locations, water cooling, and air venting.
Creating 2D and 3D part files is a simple process using current software. Instead of using a drafting table and pencil, parts are designed completely in software first. Then 3D assemblies can be created to analyze the parts and how they will work together with other parts, if required. After the design is ready to be submitted to the injection molder, then the manufacturing considerations come into play.
Establishing the part design in 2D and 3D parameters first makes it possible to evaluate the part from a mold design perspective before starting production. This saves time and cost by eliminating trial and error, and it makes the transition from design to production a smoother and more direct process. Also, making changes to the part is a simple software process that only requires making changes to the design and re-generating the part file.
Using computer aided engineering software to produce the part files for injection molding makes it easier to evaluate and adhere to the following design considerations:
- Maintaining uniform wall thicknesses to minimize sinking, warping and improve mold fill
- Using a generous radius at all corners to avoid sharp corners that increase stress concentration, which can lead to part failure
- Designing parts with sufficient draft angles for easy removal from the mold
- Using ribs or gussets to improve part stiffness and avoiding the use of thick sections
3D part files can also be used for materials analysis and stress testing in computer simulations. This makes it possible to evaluate part designs for overall quality and structural rigidity, in addition to injection molding manufacturing considerations.
Creating computer generated 2D and 3D part files is state of the art for designing parts for injection molding. Using this technique is the best way to maximize part quality and minimize production problems in the molding process.
Crescent Industries has a competitive advantage because we can aid our customers in complete product development. Our engineers have over a combined total of 90 years of plastics and plastic tooling experience therefore we are cable of assisting our customers whether they have a simple or complex project. For more information on our design and development services, click here.
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