Product design
Rapid Prototypes
Custom molds - plastic molds
Plastic molding
Production tooling

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Rapid Prototyping Prototypes
Custom molds - Plastic molds

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Product Design contract
Rapid prototyping prototype Creation
Custom molds
Production tooling - manufacturing

The process of plastic molding facilitates enhancement of part functionality and product cost reduction. For example, the cost of adding functional details to the part, by modifying the mold, are usually insignificant when amortized on a per-produced-piece basis. Molds reproduce many features for practically no cost. Ideally, all aspects of a design are evaluated with a view toward optimization, including part and hardware consolidation, finishing considerations, and markings and logos, which are discussed in this section.

Consolidation

This consists of reducing the number of parts in an assembly via part consolidation. It must be done within the constraints of good molding practice and practical mold construction. The functionality of two or more parts can be consolidated into one.

Hardware

The necessity for hardware fasteners such as screws, nuts, washers, and spacers can be eliminated through intelligent mold design. Molded-in hinges can replace metal ones in many applications. Molded-in cable guides perform the same function as metal ones at virtually no added cost. Elimination of hardware from designs cuts material and assembly costs, and simplifies dismantling for recycling.

Finish

So that the molded part does not have to be painted, pigment can be included in the raw plastic. The cost savings tends to more than justify any increase in cost for the colored material which satisfies the exposure specifications. If you must paint, select a plastic that paints easily, preferably one that does not require surface etching and/or primer for adherence.

Markings and Logos

Secondary methods of adding directions, markings, and logos — including labels, decals, printing, stamping, etc. — add material and labor costs. When these are molded into the part, material and process costs are eliminated and the markings are usually more durable. Mixtures of gloss and texture can increase contrast for improved visibility.

Miscellaneous

Look for opportunities to add easily-molded features to simplify assembly and enhance product function such as aligning posts, nesting ribs, finger grips, guides, stops, stand-offs, hooks, clips, and access holes.

Product design

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Plastic molds
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