Generally speaking, Design for Manufacturability (DfM) is the process of consciously and proactively designing products to optimize all facets of manufacturing.
DfM methodology aligns engineering and production in the design phase, ensuring cost and time efficiencies, superior quality, regulatory compliance, and end-user satisfaction.
Central to maximizing these DfM benefits is prioritizing Failure Mode Effect Analysis (FMEA) within the larger plastic part analysis to assess risk probability. Identifying and addressing problems early in the product development process prevents costly issues that could impact manufacturability such as plastics selection, tight tolerances, and secondary operations.
An estimated 80% of a project’s costs are determined within the design phase.1 For injection molded parts, tooling often consumes a good share of the budget and decision-making, but it’s not the only consideration.
Value-added services (also known as secondary operations) are essential and sometimes overlooked during design because of their injection molding post-processing status. However, identifying the proper value-added services early in the project timeline can help eliminate injection molding defects that could ultimately lead to costly fixes.
From excessive energy consumption and scrap to general resin use, the injection molding process has historically raised some ecological concerns. The alarm is neither surprising nor unique to injection molders or the industries they serve.
However, as some experts project that the earth may be mere decades away from environmental collapse1, there are important choices to be made.
Manufacturers across industries continue to rely heavily upon custom injection molders to help design, engineer, and produce solutions for complex applications. Not every molder is capable of delivering on these expectations, but those that are will undoubtedly insist upon exceptional injection molding quality control.
As a trusted partner to OEMs in medical, automotive, industrial, and consumer markets Kaysun is deeply committed to quality and the processes necessary to maintain it. Through strategic implementation of quality assurance initiatives and continuous improvement cycles, our customers are confident in attaining desired results.
Up until World War II, achieving necessary product functionality at the lowest cost was usually done by any means necessary. However, the war-related scarcity of materials and parts compelled General Electric engineers to find material substitutes.
Many of the substitutes reduced project costs and improved overall product performance — and the standard practice of finding cost-effective manufacturing solutions without compromising product functionality or quality was born. Today, we know it as "value analysis" for existing parts or “value engineering" for new parts.
OEMs across many industries can attest to the benefits of plastic injection molding. It’s ideal for consistent, affordable production of a wide range of high-quality complex plastic parts that can withstand about any environment.
That’s reason enough to rank injection molding high on the list of go-to solutions, but there’s more. To better understand how and why manufacturers use the process, let’s take a look at the individual merits of the top 14 benefits of plastic injection molding (listed in no particular order):
Plastic injection molding automation is a staple for custom injection molders, and with good reason. The speed and precision automation lends to producing extremely complex injection-molded parts is unparalleled. Automation also helps realize cost efficiencies by eliminating humans — and the related potential for error — from the process.
With so many benefits, it’s easy to understand why plastic injection molding automation is appealing to OEM and molder alike. What makes it even more valuable is when a custom injection molder has an in-house automation team available to develop creative turnkey solutions to even the toughest customer challenges.
Confusion about which plastics align with a particular application can cause uncertainty about if and when to use custom injection molding. As a result, OEMs may not take advantage of how plastics benefit product design.
“Thermoplastic” and “thermoset” sound similar and both plastics categories offer choices appropriate for complex applications in a range of markets. However, it's the properties and processing behaviors of the materials within the categories that ultimately reveals the best choice for your injection molding project.
A surprising number of projects are completed without using a prototype tool. The general idea is that prototype tooling is an extra, unnecessary step that increases cost and decreases development and production times.
Actually, the opposite is true. Custom injection molding done without a prototype tool typically leads to a series of required production tool adjustments that are both costly and disruptive. The perceived savings of skipping prototype tooling quickly evaporate, and the higher risk of part defect introduces the possibility of incurring legal expenses and other related costs.
Depending on the complexity of the application, prototype tooling generally accounts for about 20-40% of overall production tooling costs. It's not an insignificant investment, but one that's well worth it when you consider the advantages.