Featured Resources
Not Every Undercut Needs a Slide
Undercuts are often viewed as one of the most expensive features in injection molded parts. And for good reason. A relatively small undercut can trigger the need for: In many cases, the tooling required to release the undercut costs significantly more than the feature itself. However, not every undercut requires a moving mold component. Some
When a Plastic Part Needs Metal: Designing for Insert Molding
Plastic parts are remarkably capable. Modern engineering resins can withstand significant loads, resist chemicals, survive harsh environments, and replace metal in many applications. Yet even the best plastic materials have limitations. Threads wear out. Bearing surfaces degrade. Fastener locations strip. Repeated assembly causes damage. When these failures occur, the solution is not always a stronger
Designing for Overmolding: Bonding Matters More Than Geometry
Overmolding is often presented as a way to combine two materials into a single component. That description is technically correct, but it overlooks the real engineering challenge. The difficult part is rarely molding the second material. The difficult part is ensuring that the second material remains attached throughout the life of the product. In many
The Real Cost of Complex Features in Injection Molded Parts
Many of the most useful features in plastic part design are also the ones most likely to complicate a mold. Snap fits eliminate screws. Living hinges eliminate assembly operations. Overmolded grips improve ergonomics. Bosses provide attachment points. Logos and molded text enhance product branding. From a product design perspective, these features often make perfect sense.
Most Ejector Pin Problems Are Actually Part Design Problems
Ejector pins are among the smallest components inside an injection mold, yet they are often involved in some of the most frustrating production issues. When customers notice ejector pin marks, witness circles, deformation, or inconsistent ejection, the discussion usually focuses on the pins themselves. In reality, ejector pins are rarely the root cause. More often,
Most Injection Molding Gating Problems Start Before the Mold Is Built
When an injection molded part shows short shots, weld lines, sink marks, flow hesitation, or cosmetic defects, the first reaction is often to adjust the molding process. Sometimes that works. More often, the root cause is already built into the tool. In many injection molding projects, gate location and gate design have a greater impact
Designing Plastic Threads for Injection Molding: What Works and What Doesn’t
Learn how to design molded threads for injection molded parts. Explore thread geometry, internal vs. external threads, inserts, tooling considerations, and DFM best practices.
Solving Wall Thickness Problems Before They Become Molding Problems
During DFM reviews, wall thickness is one of the first things we evaluate. It is also one of the areas where we find the most preventable design issues. Many plastic parts look perfectly reasonable in CAD. The geometry may satisfy functional requirements, fit within the assembly, and meet cosmetic expectations. However, once the part moves
Injection Molding Costs Are Determined Long Before Production Begins
Many teams begin discussing injection molding costs after receiving tooling quotations. By that point, most of the important cost decisions have already been made. The geometry has been finalized. The material has been selected. The assembly strategy has been defined. The mold concept is largely determined. In other words, the majority of injection molding costs
Designing Molded Text: Small Features, Big Manufacturing Consequences
Almost every plastic product contains molded text. Examples include: From a CAD perspective, adding text is simple. From a molding perspective, text becomes another geometric feature that must: Many text-related defects are not caused by the text itself. They are caused by text being designed without considering how molds are manufactured and how plastic behaves
Not Every Undercut Needs a Slide
Undercuts are often viewed as one of the most expensive features in injection molded parts. And for good reason. A relatively small undercut can trigger the need for: In many cases, the tooling required to release the undercut costs significantly more than the feature itself. However, not every undercut requires a moving mold component. Some
When a Plastic Part Needs Metal: Designing for Insert Molding
Plastic parts are remarkably capable. Modern engineering resins can withstand significant loads, resist chemicals, survive harsh environments, and replace metal in many applications. Yet even the best plastic materials have limitations. Threads wear out. Bearing surfaces degrade. Fastener locations strip. Repeated assembly causes damage. When these failures occur, the solution is not always a stronger
Designing for Overmolding: Bonding Matters More Than Geometry
Overmolding is often presented as a way to combine two materials into a single component. That description is technically correct, but it overlooks the real engineering challenge. The difficult part is rarely molding the second material. The difficult part is ensuring that the second material remains attached throughout the life of the product. In many
The Real Cost of Complex Features in Injection Molded Parts
Many of the most useful features in plastic part design are also the ones most likely to complicate a mold. Snap fits eliminate screws. Living hinges eliminate assembly operations. Overmolded grips improve ergonomics. Bosses provide attachment points. Logos and molded text enhance product branding. From a product design perspective, these features often make perfect sense.
Most Ejector Pin Problems Are Actually Part Design Problems
Ejector pins are among the smallest components inside an injection mold, yet they are often involved in some of the most frustrating production issues. When customers notice ejector pin marks, witness circles, deformation, or inconsistent ejection, the discussion usually focuses on the pins themselves. In reality, ejector pins are rarely the root cause. More often,
Most Injection Molding Gating Problems Start Before the Mold Is Built
When an injection molded part shows short shots, weld lines, sink marks, flow hesitation, or cosmetic defects, the first reaction is often to adjust the molding process. Sometimes that works. More often, the root cause is already built into the tool. In many injection molding projects, gate location and gate design have a greater impact
Designing Plastic Threads for Injection Molding: What Works and What Doesn’t
Learn how to design molded threads for injection molded parts. Explore thread geometry, internal vs. external threads, inserts, tooling considerations, and DFM best practices.