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Article
As product development cycles accelerate, engineering leaders face a recurring strategic question: How fast can we prototype—and where does it make financial sense to build? With premium compensation levels for mechanical engineers (especially with seniority and years of experience), the opportunity cost of hands-on prototyping has never been higher. When factoring in loaded labor rates, […]
Article
Metal assemblies refer to both the process and the finished result of connecting multiple metal parts to form a durable, functional product or subassembly. This can be achieved through methods such as welding, riveting, brazing, or fastening with screws and bolts. The approach used depends on the required strength, precision, and application of the final […]
Article
Top DFM Tips, Finishing Choices, and BOM Consolidation Strategies In October 2025, Fictiv’s manufacturing experts hosted an in-depth training session in Mesa, AZ, covering advanced topics in surface finishing, Bill of Materials (BOM) consolidation, and Design for Manufacturing (DFM)—including guidelines to follow and when to push their limits. Led by Robbie Long, Tessa Axsom, and […]
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
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
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 […]
