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David Willson

David Willson holds a Bachelor's degree in Mechanical Engineering from Northeastern University and has over ten years of experience in product development and manufacturing. He creates technical content and lives in California.

All articles from the author

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The Impact of AI in Mechanical Engineering

Artificial Intelligence (AI) is transforming various industries, and mechanical engineering is no exception. When I started working as a mechanical engineer 13 years ago, I didn’t think much about AI someday replacing my job. Now, with the recent hype around AI, many of us in product development, engineering, and manufacturing have considered how AI affects […]

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Single-Minute Exchange of Die (SMED): Optimizing Injection Molding Efficiency

SMED (Single-Minute Exchange of Die) is a trending methodology used in injection molding to reduce the time required for tooling changeovers in production facilities. Manufacturers can significantly boost productivity by focusing on lengthy die changeover times as a primary source of inefficiency while aligning with lean manufacturing principles in injection molding. This article explains the […]

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Multi-Cavity Injection Molding for Higher-Volume Production Efficiency

Injection molding is a fundamental manufacturing process that allows for precise and efficient production of plastic parts. In high-volume manufacturing, multi-cavity molds play a crucial role in meeting the demands of mass production while maintaining both product quality and cost-effectiveness. By enabling the production of multiple parts in a single molding cycle, multi-cavity molds have […]

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Product Development Process: Design Phase of a Multi-Tool Phone Stand From Concept to Prototype

Product Concept Development This article will take you through the process of physical product development, starting with the essential step of developing the product concept.  Problem Statement What product would mechanical engineers want to have by their side at all times? That’s what I asked myself as I embarked on this design project.  As with […]

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Die Casting: Overview, Materials, Process, & Applications

What Is Die Casting? Die casting is a process where molten metal is cast into a mold, forming the desired part shape. Typically, a non-ferrous alloy like aluminum or zinc is used. This manufacturing process enables the creation of intricate geometries with a focus on efficiently producing large quantities of parts with high precision. Some […]

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The Future of Injection Molding: 7 Trends to Watch in 2025 and Beyond

Advancements in technology and shifting customer demands are shaping the future of injection molding. As the political landscape changes and the industry continues undergoing digital transformation, key trends such as mold transfer, automation, and on-demand production are becoming increasingly important. This article explores injection molding trends to watch in 2025 and how they will influence […]

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What is Nearshoring and Why are Companies Moving Their Manufacturing Closer to Home?

Your manufacturing partner and their location are critical factors to consider when it comes to part production. Many companies that outsource manufacturing or own factories overseas are nearshoring due to several advantages such as reduced lead times, improved communication and cost savings. Nearshore manufacturing is a trending topic in the U.S. due to these benefits […]

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Advanced Materials Guide for Injection Molding

The advent of CAD systems, additive manufacturing, and CNC machining have made the design and manufacture of complex part designs almost routine. Engineers today are tasked with designing components that may be subjected to a variety of factors, including extreme weather conditions, chemicals, bodily fluids, high stress or loads, impacts, and other elements that could […]

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Tips to Reduce Injection Molding Costs

What’s the best way to achieve low-cost injection molding? The first step is to identify and understand the sources of your expenses. Next, it’s critical to make cost-saving decisions as early as possible in the design process to avoid getting locked into a course of action that’s difficult and expensive to change later on. Discussed […]

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Chem Film, Anodizing, and Black Oxide: Which Conversion Coating is Right for Your Project?

‍When metal is exposed to the elements or certain chemicals, deterioration in the form of oxidation may occur. The Second Law of Thermodynamics declares that everything tends to move into a state of disorder. After designing and manufacturing your products, the last thing you want to discover is a breakdown of a metal component in […]

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Injection Molding Tooling: The Complete Guide

Known for quickly producing parts with consistent precision, injection molding is one of the most popular methods for creating high-quality plastic components. This manufacturing process creates parts by forcing molten plastic into a mold at high pressure, which cools and solidifies into the desired shape. It’s used across various industries to efficiently produce complex, durable […]

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CNC Stepover Guide: Understanding Its Impact on Surface Finish and Machining Efficiency

CNC stepover is the distance between successive passes of a cutting tool during computer numerical control (CNC) machining. It’s a critical parameter because it affects both the machining time and surface finish of your parts. Different machining operations need different stepover values, and the optimal value to use also accounts for the tool and the […]

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CNC Machining Outsourcing: Fictiv’s Detailed Guide

CNC machining outsourcing is a manufacturing strategy that involves contracting with another company for CNC machining services. Whether for prototyping or production, product designers who outsource their machined parts gain access to advanced technology, leverage custom machining solutions, and avoid expensive investments in equipment and training.  This guide provides an overview of computer numerical control […]

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APQP: Advanced Product Quality Planning Explained

Does the part or product you’re designing fully consider your customer’s wants, needs, and expectations? That’s where Advanced Product Quality Planning (APQP) can help. APQP is a structured approach companies use to design, develop, and launch products that consistently meet customer requirements for quality. APQP provides a framework to identify potential problems early in the […]

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Casting vs. CNC Machining: Which Process Is Best for Your Part?

We’re no longer in the Bronze Age, but some manufacturing techniques stand the test of time. Casting, a process where molten metal is poured into a mold, has been around for over 6,000 years and is still widely used and prominent in manufacturing to this day Advances in casting technology enable the casting of high-quality […]