Once the early part concept has been approved, our Genesis Design and Engineering Team perform further analysis to ensure manufacturing feasibility of the thinnest, strongest design in the optimal mold configuration.
Their analysis may include light weighting and Finite Element Analysis (FEA) of the 3D part model, applying our light weighting experience in thin wall packaging to designing a new lighter product design.
The challenge is to design the thinnest moldable parts that will still meet certain strength; deflection and surface finish criteria, especially if using specialized or exotic resins. FEA measures part deflection, stiffening, lateral loading, compressive strength, and determines the optimal strength-to-weight ratio to reduce the maximum stress points within the part.
For more aggressive applications, Mold Filling Analysis (MFA) determines numerous mold design parameters including the optimal number and position of gates, gas trap venting and processing issues like injection speed and pressure, filling patterns, cooling patterns and weld/meld line placement.
Additional considerations like part design features which enable post mold assembly and decoration, stacking, packing and palletizing can be analyzed and predicted prior to mold construction.
Identifying problems and issues during early design feasibility saves expensive rework at the prototype testing stage and can generate significant cycle time and resin savings.