Simplifying Part Design To Lower Manufacturing Cost

Complex part designs can significantly increase tooling and manufacturing costs. Simplifying geometry ensures easy mold flow, faster cycle times, and lower machining requirements.

Design simplification ideas:

• Eliminate unnecessary curves or cutouts
• Reduce undercuts wherever possible
• Minimize deep ribs and bosses
• Avoid extremely tight tolerances unless required

A streamlined design not only reduces machining complexity but also extends mold life.

Optimizing Wall Thickness For Cost Efficiency

Uniform wall thickness is one of the most effective methods to reduce molding defects and minimize cost. Thick walls increase cooling time, cycle duration, and the risk of warpage.

Best practices include:

• Keeping wall thickness consistent across the part
• Using ribs instead of thick walls for strength
• Ensuring smooth transitions between thick and thin areas

Uniform walls allow faster mold cooling and a predictable manufacturing cycle.

Improving Cycle Time For Higher Output

Cycle time directly affects cost per part. A shorter cycle means more manufacturing in less time, resulting in reduced energy consumption and greater output.

Ways to reduce cycle time:

• Improve cooling channel layout
• Use conformal cooling techniques
• Increase automation where possible
• Optimize injection speed and pressure settings

Every second saved per cycle creates massive long-term savings, especially in high-volume manufacturing.

Reducing Mold Complexity To Save Tooling Costs

Tooling can account for a major portion of injection molding expenses. Reducing mold complexity ensures faster machining, lower maintenance, and improved durability.

Strategies to simplify tooling:

• Reduce the number of cavities only if volume permits
• Avoid slides and lifters unless absolutely necessary
• Implement simple parting lines
• Use a standard mold base.

A simplified mold also reduces the risk of premature wear or tooling breakage.

Avoiding Unnecessary Tight Tolerances

Designers often use tight tolerances even when they are not needed. This increases machining difficulty and raises overall cost.

When deciding tolerances:

• Wider tolerances for non-critical areas
• Confirm tolerance requirements with functional needs
• Minimize post-processing by designing accurately

Proper tolerance planning can significantly lower waste and improve production speed.

Using Draft Angles To Improve Mold Release

Draft angles ensure the molded part ejects easily from the mold. Without drafts, parts may stick to the cavity, increasing cycle time and risking damage.

Draft angle tips:

• Add minimum 1–2 degrees where possible
• Increase draft for textured surfaces
• Ensure uniform draft across vertical walls

Applying drafts correctly prevents stress marks and reduces ejection force.

Adopting Automation To Reduce Labor Cost

Automation improves consistency and minimizes human error. While initial setup cost may be higher, long-term savings are substantial.

Examples of automation in molding:

• Robotic part removal
• Automated packaging
• In-line quality inspection
• Automatic material feeding systems

Automation becomes essential for high-volume projects where accuracy is critical.

Controlling Scrap Rate For Better Profitability

High scrap rate increases material waste and time loss. Designers should focus on mold flow, gating, and filling patterns to minimize defects.

Ways to reduce scrap:

• Optimize gate placement
• Adjust flow paths for uniform filling
• Use simulation to identify potential defect zones
• Test prototypes early

Small improvements can reduce scrap and boost overall efficiency.