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Injection Molding Comprehensive Processing Guide: Eight Elements To Reduce Injection Part Mold Costs

Views: 0     Author: Site Editor     Publish Time: 2023-10-15      Origin: Site

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Every business seeks to minimize part manufacturing expenses. One common strategy is to maximize the utilization of molds by producing a larger quantity of parts, thus distributing the initial mold design and machining costs across a greater number of units. ZONZE employs a similar approach, leveraging the versatility of molds to manufacture multiple zero parts, effectively reducing manufacturing expenditures. Now, let's explore the key factors involved in this cost-saving process.

How much does injection molding cost?


While injection molding initially entails higher costs than methods like CNC machining and 3D printing, its cost-effectiveness becomes apparent when producing large quantities of parts. The pivotal cost determinant in injection molding is the time needed to fabricate molds, meaning that intricate part geometries incur higher expenses. Drawing from ZONZE's twelve-year expertise, it has been discerned that the most economical parts are those devoid of complexities such as undercutting or intricate surface treatments.

 

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Apart from unit cost, the choice of materials is crucial to the injection molding process. While several plastics share similar strength and functionality, certain materials are inherently more moldable, thus lowering part costs. When submitting your designs to ZONZE, our engineers will offer insights into process optimization tailored to your product's intended application, expedite the prototyping phase, and present scalable production solutions.


Outlined below are eight key design considerations for injection molding that can effectively minimize manufacturing expenses:

• Conducting thorough DFM analysis 

• Eliminating undercuts 

• Removing redundant features 

• Employing the core and cavity method 

• Opting for simplified surface finish and appearance 

• Designing self-fitting components 

• Utilizing multi-mold-cavity or family molds 

• Choosing the Production on Demand option



Formability-DFM analysis


At ZONZE, we offer a complimentary Design for Manufacturing (DFM) analysis with every injection molded part quotation. This analysis helps pinpoint potential problem areas or opportunities for design enhancement, such as inadequate draft angles or unfeasible geometries. We encourage you to thoroughly review these insights and reach out to your dedicated ZONZE sales professional with any design-related inquiries.

undercut


Undercut features pose significant challenges in part ejection during injection molding, potentially leading to complications or even hindering part ejection entirely. While eliminating undercuts is ideal, certain design requirements may necessitate their presence, such as for side actions or sliding components. An alternative approach involves employing sliding shutoff valves or simplifying mold design by adjusting the parting line and extraction angle, thereby reducing manufacturing costs by eliminating the need for additional mold components. Moreover, minimizing the use of manual inserts and streamlining mold operations can further mitigate manufacturing costs by reducing cycle times and manual intervention.

Unnecessary functions


While textured surfaces, molded part numbers, and company logos add aesthetic appeal to injection molded parts, they incur additional costs. However, permanent part numbers are essential for various applications, notably in aerospace and military sectors. When incorporating part numbers, opt for factory-appropriate fonts like CenturyGothicBold, Microsoft Black, Microsoft YaHei, or Verdana (sans-serif fonts), ensuring they are at least 20 pounds in size and no deeper than 0.25 mm to 0.38 mm. Additionally, consider adding extractor dies if part release is a concern.

core cavity


When producing electronics enclosures or similar box-shaped parts, you have two options: countersink the wall cavity to the bottom of the mold and machine ribs using a long, thin tool, or utilize the core cavities method by machining the aluminum material around the core and shaping it around the part. The latter approach, core cavities, proves to be more economical and offers advantages such as smoother surface finishing, enhanced venting, improved part release, and elimination of the necessity for steep draft angles.


surface treatment


Achieving superior exterior aesthetics in parts often necessitates additional processes like sandblasting, EDM, or advanced mold polishing, inevitably leading to increased costs. Any injection molded component surpassing a PM-F0 finish level will demand secondary procedures, such as polishing to an SPI-A2 mirror finish utilizing a Class 2 diamond polishing wheel, further escalating expenses. It's advisable to avoid opting for such meticulous surface finishes unless explicitly required by the project.


Self-fitting parts


Consider designing a cassette for a medical device or a housing for a portable radio: why opt for two separate parts when one can suffice? By integrating a snap mechanism into the splice part, both halves can effortlessly assemble from either side, yielding a "universal" component that streamlines production with just a single mold.

Multi-cavity and series molds


Perhaps expanding your production volume could be advantageous. Even with aluminum molds, incorporating configurations of two, four, or eight cavities allows for elevated throughput rates, contingent upon part size and complexity. While this approach may influence tooling expenses initially, it has the potential to drive down the unit cost of each part.

 

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Do you possess a collection of parts that exhibit compatibility for amalgamation? Consider the feasibility of consolidating multiple molding projects into a singular endeavor. By ensuring uniformity in material composition, size consistency, and cavity accommodation, it's plausible to produce them collectively without necessitating individual molds. Alternatively, contemplate integrating movable hinges to facilitate part assembly and enhance manufacturing efficiency.

on-demand option


To mitigate injection molding expenses, exploring on-demand manufacturing proves beneficial. At ZONZE, we offer tailored injection molding services designed to cater to diverse project needs, including single-color injection molding, two-color injection molding, overmolding, insert molding, and nano-injection molding. Our on-demand manufacturing services accommodate different quantity levels, enabling efficient management of parts demand fluctuations and overall cost reduction.


summarize

Injection molding stands out as a versatile and efficient technology, delivering top-notch, tailored plastic parts across various industries. Prioritizing effective mold cost control during the design phase is crucial for economical production and swift cycle times. Reach out to ZONZE today for expert guidance on your injection molding design, and let us help you achieve optimal outcomes.



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Zonze focuses on multi-process assembly services, facilitated by its array of metal and plastic product processing workshops.

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