Medical_Group_Feb_2016_Pic_3A.jpgMinimizing risk for outsourced custom injection molded plastic components is accomplished by using the right tools.  Here are some of the tools that can be used to mitigate risk for your injection molded components. A well defined quality management systems that relies on Product/Process Failure Mode and Effect Analysis (PFMEA). Utilizing Mold Fill Simulation to minimize any potential for risk.  

Understanding PFMEA

It is only when these tools are well understood that the management and application of both PFMEA will be recognized as the most efficient and effective approach. Results are everything, and results are only achieved when these methods are properly applied.

To better understand PFMEA use potential, it is important remember;

  • Product/Process Failure Mode and Effect Analysis (PFMEA) is a quality engineering tool used to quantify and evaluate the process variables used in the injection molding process
  • Utilizing PFMEA as a structured approach to identifying, estimating, evaluating and prioritizing risk delivers higher product quality
  • PFMEA identifies critical input and process variables that can affect product quality, it formulates assumptions about the relationships between variables that can affect product quality and it provides a means to more fully evaluate the risk associated with product defects in order to mitigate that risk
  • RPN is used to calculate the relative risk associated with defects.  This must be calculated for the entire process or design.  After the RPN is calculated, the failure modes with the highest RPN are assigned the highest priority when corrective action is considered

Why Mold Fill Simulation for Custom Injection Molded Plastic Components

Mold Fill Simulation delivers a realistic means to anticipate critical factors in the manufacturing process for your custom injection molded plastic parts. Comprehending the value of this process also relies on a full understanding of the following factors;

  • A comprehensive understanding that this is the process of utilizing software to virtually simulate the filling, packing and cooling a molded plastic part
  • Realizing that this process allows for critical decisions to be made before the mold is manufactured and when design changes are less expensive  
  • Remembering that the simulation is a visual representation of how the mold will fill – showing areas of the part that will not fill completely with plastic. This means exposing where the weld lines  develop and whether these weld lines will be structurally sound
  • Knowing that the mold design can simulate different gate locations that can improve the manufacturing situation
  • Making informed determinations concerning specific resins and evaluating material sheering, temperature and pressure. This can help you decide if a specific material will work with a given part design  
  • Knowing that the cooling lines can be analyzed in the mold design.  The heating and cooling of the mold can be simulated through the entire molding cycle, over multiple cycles to help determine the size  and location of cooling lines.  Since cooling lines affect how or if the part warps, this allows for the potential warpage of the part to be viewed  
  • Realizing just how useful it is for molds that produce multiple components - and to show whether or not the parts fill at the same time so that adjustments can be made to the parts, runners and gates.
  • These capabilities can also be useful on existing molds to point out fixes for molds that have issues such as uneven fill times between parts, and identification of any potential trouble filling and heating or cooling these components during manufacturing  

Today’s plastic injection molded components are improved by the overall quality, reduction in failure rates and minimization of risk through the use of these complimentary tools. Contact Crescent Industries today for your project evaluation.

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Topics: custom injection molding