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Article
Warping is a common defect in injection molding that creates distortion of a plastic part after ejection. Warpage is caused by uneven shrinkage, as a result of residual stresses or cooling imbalances, and often appears as twisting, bending, or dimensional inaccuracy. Root causes include nonuniform wall thickness, improper mold design, material shrinkage rates, and inadequate […]
Article
Heat staking is a process that reshapes thermoplastic features to form secure mechanical connections with other components. It offers a clean, durable assembly solution when you need to join plastic and metal parts without visible fasteners. It is used across various industries from automotive to medical devices. How The Heat Staking Process Works Heat staking, […]
Article
Manufacturing is difficult enough without knowing the language most manufacturers use. Here’s a quick resource to help you learn the most common terms for describing physical parts. Fundamental DFM Terms Across Processes Undercut In manufacturing, an undercut is a recessed or overhanging feature that obstructs direct tooling access. There are various solutions to undercuts, although […]
Article
Ultrasonic welding is a joining method used across industries where parts are made from thermoplastics, metals, or other compatible materials. Its ability to quickly produce clean, reliable joints has made it indispensable in fields ranging from medical device manufacturing to automotive systems and consumer electronics. For teams focused on design for manufacturability (DFM), understanding ultrasonic […]
Article
Micro molding is more than just the manufacturing of small plastic parts; it represents a highly specialized apex of injection molding, where precision is measured in microns and tolerances are tighter than a human hair. It is the enabling technology behind modern medicine’s life-saving catheters, connectors found in your smartphone, and fluid circuits that enable […]
Article
When we talk about Six Sigma today, particularly in the context of manufacturing, we’re referring to a systematic way of making processes more reliable, efficient, and nearly error-free. Initially developed as a quality control system for large-scale manufacturing operations, Six Sigma’s primary goal was to improve processes while reducing the number of defects. Over time, […]
Article
Sheet metal fasteners, such as self-clinching nuts, studs, and standoffs, provide strong, reusable threads in thin sheet assemblies where traditional methods like welding or tapping are not feasible. These fasteners are pressed into pre-punched holes, displacing the surrounding material to form a permanent, load-bearing anchor. They are widely used in electronics enclosures, aerospace panels, and […]
Article
Whether you’re in early development of a medical device, a consumer electronics accessory, or a simple cable clip for your desk, the goal is usually the same: to test the concept as quickly as possible. When it comes to getting your product from a digital idea on screen to something physical in hand, prototyping is […]
Article
Injection molding is one of the most versatile and powerful methods for producing plastic components at scale. Its ability to deliver complex, durable, and cost-effective parts has made it indispensable across industries. But the secret to consistent molding success isn’t just in the part and mold design—it’s in the process. The line between a flawless […]
Article
In product development, the rapid prototyping stage is one of the most important, iterative, sometimes hectic, and hopefully fun. There’s nothing like cranking out prototype iterations overnight, to come back to the parts the next day and start the process again. During this phase, engineers and designers can test and validate their ideas, refining them […]
