DESIGN TIP: Cutting Corners on Injection-Molded Parts

Sharp corners definitely have their place in part design, but they often spell trouble when injection molding plastic parts. Accordingly, designers should be aware of the pitfalls associated with “being square” when developing parts. Indeed, part accuracy, strength, and aesthetics suffer without the right amount of corner rounding and filleting.

This month’s design tip explores ways to strengthen injection-molded parts while reducing costs with proper placement of corner radii and fillet. You’ll learn about:

  • Material selection. Some plastics are more forgiving of sharp-cornered parts. Choosing the right one for your application is a necessary step towards accurate, functional parts.
  • Wall thickness. Beefing up adjacent walls may absorb some of the stress associated with sharp internal corners, but can create other design challenges.
  • Part geometry. Some parts are simply more “moldable” than others. Achieving proper form, fit and function depends on sound part design, a large piece of which is appropriate corner radii.

READ FULL DESIGN TIP

WATCH: Talkin’ Cosmetic Defect Blues

The next short video in our Fundamentals of Molding series takes a trip down the Mississippi River to explore different cosmetic flaws like sink, warp and blush, which can find their way into injection-molded parts.

 

For a lengthier examination on avoiding cosmetic defects when designing for injection molding, read our free white paper.

Thirsty for more quick tips? Here’s our previous video on draft considerations:

 

NEW JOURNAL: How Technology is Transforming Injection Molding

The new issue of Proto Labs Journal is out and includes a cover story focusing on the digital transformation of injection molding. A related, second feature story explores the pros and cons of printed plastic molds.

The cover story reports on how automating the front-end of the manufacturing process has reinvented injection molding, and served as a game-changer for the entire industry.

The related feature, “3D-Printed Molds,” advises product designers, engineers and developers to take a careful look at part finish, size, design capabilities, mold longevity considerations and cost when comparing printed plastic molds to aluminum tooling.

Elsewhere in the Journal, look for our Eye on Innovation feature, which highlights cool new products and technology you should know about.

Read the entire Journal here.

We’re always on the hunt for though-provoking content, so send your cool project or article idea to our editor at angelo.gentile@protolabs.com.

Thanks and enjoy the issue!

EYE ON INNOVATION: Proto Labs Salutes ‘Smart’ Companies on MIT List

The 50 Smartest Companies for 2016, as compiled by MIT Technology Review in its recent annual list, combine cutting-edge technology with effective business models.

In our on-going quest to seek out and identify innovation in manufacturing and technology, we salute these companies that, as the MIT folks say, “are ‘smart’ in the way they create new opportunities.”

In fact, we’re pleased to serve as a prototyping and low-volumes production parts supplier for a number of these companies (though non-disclosure considerations prevent us from identifying which ones we work with). We do take satisfaction in knowing that our digital manufacturing prowess has, in key ways, helped nurture the innovation these companies are being recognized for.

As the Review reports, some of this year’s stars are giant corporations like Amazon and Alphabet, which, “are using digital technologies to redefine industries.

Others are wrestling with technological changes: companies like Microsoft, Bosch…and Intel.” Automotive leaders such as Toyota and Tesla Motors are also on the list. Plus, you’ll find ambitious startups too, such as 23andMe, an innovator in consumer-accessible DNA testing.

SEE THE MIT TECHNOLOGY REVIEW LIST HERE.

Eye on Innovation is a monthly look at new technology and products.

CASE STUDY: A Sea Change for Sailboat Winches

The story of how Proto Labs helped a French company with a revolutionary sailboat winch design started with a daring adventure at sea.

Pontos, the Saint Malo, France firm that’s reinventing sailboat winches, was co-founded by Michel Chenon and Darryl Spurling in 2010 after, as they describe it, a “hair-raising” close call that brought their sailboat dangerously close to the rocky outcrops of the narrow straits off the island of Brehat, France.

On the high seas, Pontos’ winch models have proven their worth in a variety of yacht races and regattas worldwide. Photo Courtesy: Pontos

The boat was equipped with a winch for the hoisting and furling of the sails that proved to be too physically challenging for the inexperienced crew to use.

This adventure led the two, along with a research and development team, to spend an intense three years creating and perfecting — with the help of Proto Labs’ rapid manufacturing services — the design of what would become a game-changing new line of sailboat winches. These now award-winning winches would also eventually be used on sailboats that would win or be competitive in several notable yacht races and regattas worldwide.

READ THE FULL CASE STUDY