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

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

3. 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

4. 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

5. 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

6. 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.

7. 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

8. 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

9. 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

10. 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

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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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