From the perspective of an injection mold manufacturer, we often see how early design decisions directly influence both tooling investment and long-term production costs. By considering manufacturing feasibility during the design phase, companies can avoid unnecessary expenses and accelerate time-to-market. Below are several key strategies to optimize product design:
- Simplify Geometry
Complex part geometries require more intricate molds, additional sliders, or complex ejection systems, which increase tooling cost. By simplifying shapes and minimizing undercuts, you can often achieve the same functionality with a less expensive and more reliable mold design. - Optimize Wall Thickness
Uniform wall thickness reduces the risk of warpage, sink marks, and extended cooling times. Optimizing thickness not only improves product quality but also shortens cycle time, directly lowering production costs. - Reduce Part Count Through Integration
Whenever possible, consider integrating multiple components into a single injection-molded part. This can minimize assembly steps, reduce overall mold count, and lower labor costs. - Design for Standardization
Standard mold bases, inserts, and interchangeable components help reduce tooling expenses. By avoiding custom or oversized mold components, projects can achieve faster lead times and more efficient maintenance. - Material Considerations
Choosing the right resin with good flow properties can reduce the need for high injection pressure, which in turn lowers wear on the mold and improves its lifespan. In some cases, material substitution can also lead to significant cost savings without compromising performance. - Facilitate Efficient Mold Cooling
Designing parts that allow efficient cooling reduces cycle times, which is one of the largest contributors to production cost. Strategic placement of ribs and features can improve both cooling and part stability. - Early Collaboration with the Mold Maker
Involving your mold supplier early in the product development stage allows for design feedback and feasibility checks. This collaborative approach can help identify cost drivers early and propose practical design changes before expensive tooling is committed.
At Rilong, we have over 30 years of manufacturing experience and specialize in providing one-stop solutions to our customers. From concept design, design optimization, and design validation, through to mold making, production, assembly, and packaging, we support our clients at every stage to ensure efficient, cost-effective, and high-quality outcomes.
