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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Webinar Round-Up: 3D Printing Materials, CNC Machining, and More

We wrapped up 2017 with two webinars on rapid manufacturing. First, we discussed how to design efficient parts for CNC machining. Then we shared tips on how to select the right material for your 3D-printed parts. Both are available on demand.

Stay tuned for what’s to come in 2017. We’ll be kicking off the new year by looking at how to leverage on-demand production to reduce manufacturing costs and manage demand volatility.

Proto Labs’ On-Demand Webinars 
Below you’ll find our complete library of webinars—just click the title to watch.

Designing for Rapid Overmolding

  • Design factors that determine the quality of flexible-to-rigid bonds
  • Methodology used to measure bonding strength

Designing for 3D Printing: Selective Laser Sintering

  • SLS material considerations
  • Design guidelines for functional prototypes and production parts

How to Choose the Right Thermoplastic Material

  • Factors in thermoplastic material selection
  • Overview of common thermoplastics including the effects of additives

Designing for 3D Printing: Direct Metal Laser Sintering

  •  DMLS design considerations including surface finishes, internal features, stresses, and support requirements.
  • Reducing multi-part assemblies into a single component

DESIGN TIP: 6 Undercut Techniques to Improve Moldability

Undercuts are those complex features in an injection-molded part that prevent its ejection from the mold. They can be found on thousands of everyday parts, from the threads on a fastener to the slot for the power switch on a smart phone case.

The left image (1), illustrates a clip with undercut feature. The right image (2), shows an access hole beneath the undercut that allows the mold to protrude through the part and provide the needed latch shutoff geometry.

In our latest tip, we cover different injection molding design techniques to successfully integrate undercuts, and ultimately, improve overall part moldability.

This month’s tip discusses:

  • Parting lines
  • Side-actions
  • Bumpoffs
  • Hand-loaded inserts
  • Telescoping shutoffs
  • Additional considerations

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On-Demand Injection Molding Helps Med Device Firm Bring Vision to Blind

Helping blind people gain a sense of vision—and doing so through their tongues—sounds like pure science fiction.

Wicab Inc.’s BrainPort V100 is a wearable device for the blind that enables users to process visual images with their tongues.

It’s now a reality, however, thanks to the BrainPort V100, a wearable medical device developed with help from Proto Labs’ injection molding production process. The device enables users to process visual images with their tongues, and users say the effect is like having “streaming images drawn on their tongue with small bubbles,” according to Wicab Inc., the BrainPort’s Wisconsin-based maker.

That comes from the vibrations or tingling that users feel on the surface of their tongue as information about their environment—captured by a small video camera on the BrainPort headset—gets converted into patterns of electronic stimulation through a small, electrode-embedded mouthpiece.

The BrainPort V100, already for sale in Europe and Canada, achieved a breakthrough recently when the U.S. Food and Drug Administration (FDA) approved it as an assistive device for the blind and visually impaired to use in conjunction with other aids such as a white cane or guide dog.

Wicab turned to Proto Labs for on-demand injection molding production components to develop and launch this technology, including the existing BrainPort V100, and a new model now in development, the next generation BrainPort Vision Pro.

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