All Case StudiesConsumer Products
Consumer Product Housing
Power
Injection mold
Result
Tool-ready plastic DFM
Industry
Consumer Products
OF
The Challenge
A consumer electronics brand was moving a connected home device from SLA prototypes to injection-molded production. Early mold feedback flagged insufficient draft on snap hooks, sink marks on the cosmetic top shell, and a gate location that would leave a vestige on the visible face. Tooling deposit was due; they needed mold-ready CAD without sacrificing industrial design.
Our Approach
- Audited wall thickness, rib height, and boss proportions against ABS shrink data
- Added draft and parting-line splits coordinated with ID — hidden snap features on internal flange
- Relocated gate to underside flange; documented weld-line acceptance on non-cosmetic ribs
- Built shrink-adjusted CAD and mold-flow-informed rib layout
- Released 2D drawing with critical fits (lens stack, snap engagement) and texture callout
- Ran AI DFM pass + engineer review before mold quote
Results
12 → 0
DFM issues
Critical mold blockers cleared pre-tooling
1 round
Cycle
Single ECO loop vs typical 3–4
Tool-ready
Outcome
Mold vendor accepted package without hold