Checklist on what we usually need to discuss with client.

Part Design

1. Wall Thickness
   Avoid abrupt changes in wall thickness.Uniform wall thickness prevents warping and sink marks.
2. Ribs and Bosses
   Design ribs and bosses with appropriate thickness and spacing to support structural integrity.
   Avoid thick ribs that can cause sink marks on the opposite side.
3. Draft Angles
   Incorporate appropriate draft angles (typically 1-3 degrees) to facilitate easy ejection from the mold.
   Ensure all vertical walls have draft angles.
4. Fillets and Radii
   Use fillets and radii at internal and external corners to reduce stress concentrations.
   Avoid sharp corners to enhance material flow and part strength.
5. UndercutsMinimize undercuts as they complicate mold design and increase costs.
   Use side actions or collapsible cores if undercuts are necessary.
6. Holes and Slots
   Design holes and slots with consistent diameters and avoid blind holes where possible.
   Ensure holes have sufficient distance from edges and other holes to prevent weak areas.

Mold Design

1. Parting Line Location
   • Choose parting line locations to optimize mold manufacturing and part ejection.
   • Ensure the parting line does not intersect critical or visible surfaces to maintain aesthetic quality.
   • Avoid parting lines in areas that may affect the structural integrity of the part.
2. Gate Location
   • Choose gate locations to ensure balanced filling and minimize weld lines.
   • Avoid placing gates in visible areas to reduce aesthetic defects.
3. Venting
   • Design adequate vents to allow air to escape during the injection process.
   • Place vents at the end of flow paths to prevent trapped air.
4. Cooling System
   • Incorporate an efficient cooling system to ensure uniform cooling and reduce cycle time.
   • Optimize cooling channels for consistent temperature distribution.
5. Ejection System
   • Design an effective ejection system with sufficient ejector pins and plates.
   • Ensure the ejection system is balanced to prevent part deformation.

Material Selection

1. Material Properties
   • Select materials with suitable properties (e.g., strength, flexibility, temperature resistance) for the intended application.
   • Ensure compatibility with the injection molding process.
2. Shrinkage
   • Account for material shrinkage in the design to maintain dimensional accuracy.
   • Use material-specific shrinkage rates provided by suppliers.

Manufacturing Process

1. Mold Flow Analysis
   • Conduct mold flow analysis to predict potential issues such as warping, air traps, and weld lines.
   • Use the analysis results to optimize part and mold design.
2. Prototyping
   • Create prototypes to validate design and functionality before full-scale production.
   • Use rapid prototyping techniques to reduce lead time and cost