Background and Goals
Engineering Resource Center was approached by a leader in airway clearance technologies to mold a 6” long acetel part with .012” flatness tolerance, the concept was thought to be impossible to achieve.
ERC’s project engineer approached the task knowing that several iterations may be necessary to get the part molded consistently at the flatness requested. Design intent, or how the part would be used in production, was a key factor for ERC design engineers. Moldflow® software was used to predict the direction and amount of warp the part may have.
Validating the moldability with a flow analysis tool enabled the ERC project engineer to identify and correct potential injection molding problems as the part was designed. The simulation helps deliver results faster – reducing costs and increasing time to production.
Knowing each iteration would take time and money, ERC engineers designed the mold in a way to test several iterations quickly and cost effectively. After measuring the parts from the first trial, it was proven that the once thought to be unattainable tolerance, was in fact possible due to the upfront ERC engineering planning and insight put into the design of the mold.
Before design and engineering services were provided by the ERC, the Customer was having the part machined out of a block of plastic which required a much higher piece price compared to the ERC molded part. Keeping design intent at the forefront of the project and the customer’s goal to see a manufacturing cost savings, the ERC was able to develop a part with features that did not exist previously, while offering significant cost savings for the Customer.