DFM and FMEA Reducing Molding Risk Probability

It is generally accepted that Design for Manufacturability (DFM) implies designing products to be consciously and proactively manufactured to optimize the entire injection molding manufacturing process.

With DFM, engineering and production are integrated in the plastic design phase, resulting in improved quality, cost efficiencies, and regulatory compliance for end users.

FMEA, in conjunction with the larger plastic component analysis to assess risk probability, is crucial to maximizing these DFM benefits. In early stages of the product development process, problems can be identified and dealt with so that issues like plastic selection, tight tolerances, and secondary operations aren’t costly to resolve.

DFM for complex applications requires a lot of injection molding technical expertise, for example FMEA. In addition, it emphasizes the benefit derived from partnering with a DFM-qualified injection molder.

FEEDBACK ON THE DESIGN PROCESS IMPROVED

In detailed design, shape and tolerance are taken into account. It is only applicable to shape when standards or advanced systems are incorporated. In order to establish tolerance, one must look at how it affects the function of a part.

A proactive approach to failure prevention cuts down on time and costs incurred by anticipating failures, no matter what the design process or the plastic part analysis is. FMEAs are crucial for identifying risks, problems, and solutions.

The goal is to design and manufacture reliable products. FMEA assists engineers in evaluating, documenting, and prioritizing corrective actions based on failure modes.

Controlling risk probabilities through DFM – and FMEA in particular – in the design phase leads to increased confidence at every stage of the process, from conception to completion.

PROCESS CAPABILITIES ALIGNED WITH TECHNICAL SPECIFICATIONS

To analyze and predict plastic flow and cooling during injection molding, tool simulation software is used. In order to ensure that part design elements, such as wall thickness, draft, gate locations, geometries, etc., are appropriate, one should understand how plastic behaves inside the tool.

There are a variety of analytical software options. It is beneficial to select the appropriate program for each project in order to enhance production efficiency, process improvement, and part quality.

TOOL BUILD: REDUCED CHANGES

By managing tool build changes post-tool build, DFM analysis reduces costs. Engineers can use test results to help manufacturers reduce costs and save time by:

During the design phase, identify potential moldability problems and solutions to make tooling easier for quicker molding
A practical solution to potential project stumbling blocks must be found in order to minimize changes after toolbuild.

FABRICATION WITH LESS COMPONENTS, AT A CHEAPER PRICE, AND WITH FEWER COMPONENTS

By using fewer components, it is easier to reduce materials, frequency of ordering, and overall costs of automation. Also, it simplifies inventory management and makes field service easier for end users.

With DFM, it is possible to substitute materials and simplify fabrication and assembly, all of which lead to cost savings. By eliminating unnecessary features and secondary operations, proper part geometry enhances part quality while lowering part prices.

WHO GETS THE MOST OUT OF DFM?

Diverse industries and businesses appreciate the benefits of DFM. However, DFM’s upfront analysis and value is most evident during the development of new products:

An injection molder with proven DFM capabilities is beneficial to designers who do not have extensive experience designing plastic parts. Communication between engineers is quickly and efficiently enhanced when professional expertise and technology are available (and shared).
DFM estimates the cost per part and overall manufacturability for buyers and purchasing professionals. It also creates a production schedule by optimizing design aspects.
If you want to perform DFM analysis, pay attention to the “sweet spot”: when the design of the part is well understood, and the basic structure is defined. Before general sourcing begins, a 3D model (CAD file) is available to start the review process.

DFM GUIDANCE FROM TOPWORKS – WHY?

A DFM study by a certified injection molder is crucial for every application, whether you are in the medical, automotive, or any other industry. Providing upfront feedback can be a big help when it comes to nailing project specifications and controlling costs.

A DFM analysis must be solutions focused and collaborative, not a process. Topwoks employs a multi-disciplinary team approach, comprising of toolmakers, manufacturing engineers, coordinate measuring machine (CMM) technicians, tool and design engineers, and quality engineers for plastic parts.

A pioneer in DFM and FMEA analysis, Topwoks has the process knowledge necessary to achieve success when designing a new part. Throughout the entire process, we make sure our deep knowledge is aligned with your needs.

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