At Convert Design, we specialise in mechanical engineering design, helping businesses overcome the most common challenges in injection moulding product design. While injection moulding is one of the most efficient mass production methods, it presents several issues that can compromise product quality, structural integrity, and cost-effectiveness. Our team of expert mechanical engineering designers works closely with clients to ensure their designs are optimised for the injection moulding process. In this article, we explore the most common design challenges and how we resolve them.
Warping and Shrinkage Issues
Problem:
Warping occurs when different areas of a moulded part cool at varying rates, leading to uneven contraction and dimensional distortions. Shrinkage, on the other hand, is the natural contraction of plastic as it cools, which can result in parts that do not meet dimensional specifications.
Solution:
At Convert Design, we mitigate warping and shrinkage by:
- Ensuring Uniform Wall Thickness – We design parts with consistent wall thickness to promote even cooling and reduce internal stresses.
- Selecting the Right Material – Different polymers have different shrinkage rates. Our mechanical engineering designers carefully select materials with properties best suited for the application.
Sink Marks and Voids
Problem:
Sink marks appear as depressions on the surface of thicker sections, while voids form as internal air pockets due to uneven material cooling and packing.
Solution:
To prevent these defects, we:
- Minimise Wall Thickness Variations – We replace thick sections with ribbed reinforcements, maintaining strength without excess material.
Weld Lines and Weak Joints
Problem:
Weld lines, also known as knit lines, form where two flow fronts meet but do not fully fuse. These can weaken the structural integrity of a component.
Solution:
Our approach includes:
- Material Selection – Some materials bond better than others; we select polymers with strong molecular fusion properties.
Sustainability and Cost Efficiency
Problem:
Many businesses face challenges in balancing cost efficiency with sustainability, especially as regulations tighten around plastic use.
Solution:
At Convert Design, we help businesses achieve sustainable and cost-effective solutions by:
- Designing for Recyclability – We select materials that can be easily recycled and design parts with minimal environmental impact.
- Reducing Material Waste – By optimising gate design and runner systems, we minimise excess material usage.
Partner with Convert Design for Reliable Injection Moulding Solutions
Injection moulding design requires a deep understanding of mechanical engineering design principles, material behaviour, and manufacturing constraints. At Convert Design, our experienced mechanical engineering designers ensure that every product is optimised for manufacturability, performance, and efficiency.
If you’re facing challenges with your injection moulding project, get in touch with us today. Our team will work with you to develop solutions that meet your specific needs while maintaining high production quality and cost-effectiveness.