Nowadays, injection molding has become the most reliable and scalable method to produce plastic parts. Injection molded parts are widely used in a wide range of industries, from automotive to electronics to medical devices and consumer goods, because of their efficiency and durability. The reliability and scalability of designing injection molding are highly dependent on planning, precision, and process control.

Just like other manufacturing processes, injection molding has its disadvantages, like a simple mistake can make a huge defect in the molded part. Anyone can make a mistake while producing a plastic injection mold design: an amateur while experimenting, or an experienced designer while performing other processes. These mistakes can lead to deformed and weak plastic parts. Hence, it is important to know these five errors to avoid when manufacturing injection molding parts.

1. Poor Part Design:

Ignoring key design principles is one of the most common errors while manufacturing injection mold design. This includes non-uniform wall thickness, rib placement, and draft angles. Because of this error, we can observe several issues like sink marks, warping, short shots, or difficulty in ejecting parts from the mold. It is important to check whether the wall thickness is uniform to prevent uneven cooling. The design must be analyzed before production for easy part release.

2. Wrong Placement of Parting Lines:

Parting lines play a critical role in the process of injection molding as it divide the core and cavity separately. The success and cosmetic appearance of molded parts are dependent on the placement of these parting lines. If parting lines are not placed perfectly, it can cause a flash. That means there can be a leakage from the gap between the mold core and cavity. You also must perform more steps for ejection.

3. Incorrect Incorporation of Draft:

The draft is an angle that is used in the process of injection molding to incorporate a design so that ejection can be performed easily. The proper use of draft can also reduce the chances of warping or part breakage. This is another common error when manufacturers skip the draft or incorporate it very late in the design process. This affects the design process negatively.

4. Use of Wrong Material:

The selection of plastic material is the most important thing in the injection molding process. While selecting the material, you must check the thermal, mechanical, and chemical properties of the material as per the end use of the part. When these properties are not considered during selection, it may result in degradation, brittle parts, or poor performance in real-world conditions. Hence, you must consult with the material expert before choosing the polymer.

5. Neglecting Quality Control and Testing:

The last but most crucial mistake in the injection molding process is negligence in quality control and testing. When you skip rigorous quality checks or assume only visual inspection is sufficient, it will have an adverse impact on your final product. This results in the delivery of defective parts to the customers, which will affect your business. Hence, regular audits and sample testing are required to identify issues early and improve the quality of the product.

How OPM Helps:
OPM Plastics is one of the top mold manufacturing companies in India, which is known for its expertise in injection molding and tailored solutions for every project. Being the best plastic parts mold manufacturer, OPM works closely with clients to ensure all parts are designed with proper draft angles, optimal wall thickness, and advanced CAD & simulation tools to minimize design flaws.

As the leading mold design manufacturer in India, OPM has a team of experts who are well-versed with a deep understanding of polymer science. Depending on the requirements of the clients, OPM recommends the right material so that the customer gets a durable and reliable part in the end.

OPM is renowned as the most recommended injection molding company in India because of its utilization of the latest scientific molding techniques and automated machinery. Its technicians are well-trained and continuously optimize settings so that the chances of defects can be reduced. This company also maintains a consistent quality control system to deliver premium products to its clients every time.

Contact OPM Plastics today and experience another level of precision and expertise in the world of injection molding!