DESIGN TIP: 9 Ways to Reduce Injection-Molded Part Costs

Multi-cavity and family molds are used for a higher volume of parts, which can save costs. Shown here is an example of a family mold, used to produce the med-device part pictured.

Product designers and engineers love to trim costs on manufactured parts. This month’s design tip offers a number of injection molding considerations to improve part design and stretch your manufacturing dollar.

This month’s tip discusses:

  • Eliminating undercuts
  • Getting rid of unnecessary features
  • Using a core cavity approach
  • Altering cosmetic finish
  • Designing self-mating parts
  • Modifying and reusing molds
  • Leveraging DFM analysis
  • Using a multi-cavity or family mold
  • Considering part size

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Meet the Cool Idea! Award Judges: Chris Boyle

Chris Boyle and his company, SOLOSHOT, won the Cool Idea! Award in 2012.

The Cool Idea! Award judges are technologists, innovators, entrepreneurs, instructors, and some are even past Cool Idea! Award recipients. All of our judges have a story worth sharing, so we sat down with each for a quick Q&A to help you get to know them a bit better. In our first installment, we’re talking with Chris Boyle.

Chris is a biomedical engineer and entrepreneur from Queens, New York. He founded his first company at the age of 22, which led to a license agreement with a Fortune 50 medical device company. Since then, he has launched and funded multiple startups that range from consumer electronics to apparel. His most recent endeavor is SOLOSHOT—an object-tracking camera and recipient of the Cool Idea! Award. Chris’ close ties to the startup community and experience winning the Cool Idea! Award add a unique perspective to our panel of judges.

What are you looking forward to most about being a Cool Idea! Award judge in 2017?
I really enjoy seeing the combination of scientific and entrepreneurial passion. At its core, it’s both about combining problem solving with a passionate work ethic and it’s exciting to see those two things come together very early in the process.

Tell us about your background – what’s something about your professional life that we wouldn’t necessarily know by looking at your LinkedIn profile?
I created and sold a TV show to BermanBraun about Kiteboarding in the Dominican Republic. Continue reading

Automotive Tech Takes the Wheel at CES 2017

EYE ON INNOVATION

Take a stroll through CES 2017 and you might think you accidentally entered an auto show. As cars become venues for the latest tech, they’ve turned into centerpieces at the world’s largest consumer electronics showcase.

This year, auto manufacturers captivated attendees with demos of self-driving cars, high-performance electric vehicles, and even holographic dashboard displays. Here’s what caught our attention at the show.

The HoloActive Touch system uses reflections to produce a holographic interface.

BMW Makes Holographic Displays a Reality
Seeing new tech from BMW has become somewhat of a tradition at CES. This year was no different. Attendees were introduced to the HoloActive Touch system. It’s a free-floating, holographic display not unlike something you’d find in a “Star Wars” film. The user interface enables drivers to control the car’s functions without making physical contact with the vehicle.

A camera installed in the dashboard detects users’ movements and registers the position of their fingertips. When a fingertip makes contact with the virtual surface, a pulse is emitted and the function is activated. BMW has yet to announce a release date for the new dashboard concept, but its current gesture-controlled system will do for now. Continue reading

Video: Industrial 3D printing for Prototyping and Production

It takes more than designing a digital 3D model and pressing the print button to produce quality 3D-printed parts. Understanding material properties, support structures, post-build processing, and the differences between additive manufacturing processes all contribute to the quality of a 3D-printed part.

In this video, you’ll learn how we produce precise and repeatable results across our three industrial 3D printing processes and how you can best leverage additive manufacturing during product development.

 

 

Want to better understand the capabilities and benefits of industrial 3D printing? Check out our resources to learn more.

5 Common Rapid CNC Machining Questions

TIPS WITH TONY

Most are familiar with machining, but what makes it unique at Proto Labs? These are a few of the most common questions we receive about our rapid CNC machining service. These answers will help you optimize your design for CNC machining and determine how it can improve your product development efforts.

CNC-Machining-Block-Plastic

CNC machining is a subtractive manufacturing process that mills away at a block of solid plastic or metal.

1. What is unique about Proto Labs’ CNC machining process?
In order to efficiently machine low quantities as fast as possible, we do things a bit differently compared to a traditional machine shop. When you upload a 3D CAD file to protolabs.com, our proprietary software analyses the design, creates a quote, and generates the CNC toolpaths. By automating the front-end of the manufacturing process, we can machine a part in as fast as one day.

2. How does the quoting process work?
Once you upload your 3D CAD model to our website, the software calculates the price—not a budgetary estimate—to machine your design. Within a few hours, you’ll receive an email with an interactive quote. Here, you can select different materials and quantities and receive real-time price updates. The quote even contains a 3D-view of your machined part, which will highlight any differences between the machined part and the original 3D CAD model. See a ProtoQuote preview here. Continue reading