Design  Engineering Realisation  Engineering customer & supplier Production  supplier Validation  supplier

? C Design  Realisation Tooling Injection point Injection mark Parting lines Ejector places Functional area Draft angles Realistic tolerances ? Design  Realisation C Tooling

Design  Realisation Remember when designing: Injection point Injection mark Parting lines Ejector pins Functional area Draft angles Realistic tolerances Uniform wall thickness Design inserts Material Product specifications

Design  Cost Reducing cost when designing: Injection point Injection mark Parting lines Ejector pins Functional area Draft angles Realistic tolerances Uniform wall thickness Design inserts Material Product specifications

Design  Cost Injection point / mark Accessible point Issues example: Long runners  More material Extreem high injection pressure needed Bad design can make an easy product impossible to make

Design  Cost Parting lines Location depends on most critical issue No cavity/shape in front mold not favorable as this surface is a light press fit, but the cavity will be €heap Cavity/shape in front mold not favorable as this surface is a light press fit, and an extra cavity in front mold. Parting line on glue surface is most favourable favorable as there is room for the protruding parting line when < 0.1. But mold is impossible to make without slides due to undercut.

Design  Cost Ejector pins Location Shape: Round = standard = Cheap Secondairy function: Avoiding / reducing airtraps Compressed air will heat up and burn material, creating carbon residue and reducing the critical electron path. Also applying insert on critical location will prevent/reduce trapped air and improves manufacturability

Design  Cost Functional area Draft angles Not every part of the product is critical to function These area’s can be used for Injection point / ejector place / glue surface / draft angles / coating Draft angles ± 0,5 / 1,0 degree (general use) 0 degree is possible, but depending on design and material

Design  Cost Realistic tolerances Functional Position accuracy of 0,2 mm in assembly (specs => important) Dimension pen ø 4 (+0 / -0,02 mm) Dimension mold for pen ø 4 (+0,01 / -0 mm) The dimension is not critical when molding After validation of product, this dimension will not change If it does, then the mold is broken so production isn’t possible anymore Dimension has no added value as both mold part will close with much more accuracy, then the positioning dimension on drawing

Design  Cost Realistic tolerances Example: Functional Mold shrinkage Ø 10 mm h8  +0 / -0,022 mm Mold shrinkage Victrex 90G Along flow 1,0 % Across flow 1,3 % Absolute Shrinkage Along flow 0,1 mm Across flow 0,13 mm Shrinkage can fluctuate 0,03 mm So ø10h8 cannot be reached

Design  Cost Realistic tolerances Shrinkage is an egg of Columbus Functional Mold shrinkage Shrinkage is an egg of Columbus Essential for achieving GSA 01 0214 In combination with Pin / Insert design helium leak rate < 1 x 10-9 [mbar.l/s]

Design  Cost Realistic tolerances Example: Functional Mould shrinkage Uniform wall thickness Example: Less material thickness More material thickness Result  slightly oval product Within tolerances No functional limitation

Design  Cost Design inserts Keep it simple and functional Material change of polymer has no significant influence on cost reduction. Pin design is the most effective

Design  Cost Material Polymers Inserts Design depending Only interesting when producing in high volumes PP = ~ € 1,50 p/kg LCP = ~ € 60,- p/kg PEEK = ~ € 120,- p/kg Small production amount not influenced by material price Inserts Design depending Good manufacturable design  Less expensive

Design  Cost Mold / Tooling is expensive Efficient combining of products in one mold reduces the tooling costs per product Latest mold 6 cavities available 2 already in use Small (non PEEK) product can be made in a “pocket” mold Makes use of a general mold at Euro Techniek

C C C Design  Cost Additional costs: All movements other than the open/close direction of the mold due to the design (undercuts) Slides Mechanical / Hydraulic / Pneumatic Inclined ejector pins Collapsible cores How the edges are defined in the design Very difficult to make a sharp edge the bottom of a cavity Perfect Radius at mold parting level. This is a certain guaranty for burr forming C C C

Summary Cost reduction begins with the manufacturability of the design Main aspect: Function critical specifications Workable tolerances Effective use of tooling 1 product ≠ 1 tool