8 Design Rules for Injection Moulded Products

Injection moulding is a transformative process that allows for the efficient and cost-effective production of a wide variety of products. However, to take full advantage of the benefits this manufacturing method offers, it’s essential to adhere to certain design rules. From incorporating the right geometries to selecting suitable materials, understanding these design principles can elevate your product's quality and usability.

1. Design for Manufacturability

The foremost rule is to always design with manufacturability in mind. This means ensuring that your design can be easily and efficiently produced using injection moulding. Simple shapes, uniform wall thickness, and minimal undercuts are vital to achieving this goal.

2. Consider Wall Thickness

A consistent wall thickness is crucial in injection moulded designs. Variations can lead to deformation or warping during the cooling process. Aim for a wall thickness that is not excessively thick or thin, ideally around 1.5mm to 3mm.

3. Optimize for Shrinkage

All materials undergo shrinkage as they cool, and injection moulding is no exception. It’s vital to account for this shrinkage in your designs to prevent issues in fit and assembly. Research the specific shrink rates of your chosen material to make the necessary adjustments in your design.

4. Design for Tolerances

Injection moulded parts often need to fit together, requiring precise tolerances. Consider the functions of the parts and specify tolerances that will maintain the integrity of the assembly while acknowledging the capabilities of injection moulding processes.

5. Incorporate Draft Angles

Draft angles are essential for facilitating the easy removal of parts from the mould. Generally, a draft angle of 1 to 2 degrees is recommended, depending on the height of your part. This will help in minimizing damage during demoulding and improve the longevity of the mould itself.

6. Choose Appropriate Materials

Material selection significantly affects both the performance and aesthetic of the finished product. Factors such as strength, flexibility, color, and cost should steer your choice. For everyday household items, consider innovations in materials like Bakelite injection moulding for household appliances, and for industrial applications, Bakelite moulding for industrial applications may be ideal.

7. Plan for Assembly

If your design comprises multiple parts, consider how they will be assembled. Designing for ease of assembly can significantly reduce production time and costs. Think about snap-fit connections and interlocking features that can enhance the efficiency of assembly operations.

8. Test and Iterate

Finally, the design process doesn’t end with a final draft. Prototyping and testing your injection moulded product can surface critical insights into its functionality and manufacturability. Iterating on feedback and making necessary adjustments can lead to substantial improvements and a successful product launch.

By adhering to these design rules, several brands and creators have successfully developed injection moulded products that resonate well with their audiences. Always remember, seeking guidance from seasoned professionals, such as those from DENICE, can provide invaluable insights and support to streamline your design process.