Case Studies

Design for Manufacturing

As engineering challenges emerge in the design and manufacture of injection molded components and assemblies, the Natech engineers document their solutions to add to our expanding knowledge base.  We share the problems, design tips, and lessons learned from these experiences.  The rules of plastics provide a framework for sometimes breaking those rules when necessary.

Case Study: Capability of Elastomers

Diagnostics OEM
Challenge
A lubricious additive within an elastomer left a residue that compromised a liquid seal.
Solution and Results
The Natech Engineers tested two materials to confirm capability and statistical process control.
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Quality by Design – Snap Fit Design

A Diagnostics Client
Challenge
A snap fit failed a usability test, but the design of the hook was locked.
Solution and Results
The Natech Engineers adjusted the design of the mating component to optimize performance and reduce the economic impact.
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Design for Assembly – Tolerance Stack Analysis

A Diagnostics Client
Challenge
Four of the five component designs had already been defined in relative isolation and were already locked, but tolerances allowed for potential leakage risk during assembly.
Solution and Results
The Natech Engineers performed a tolerance stack analysis and refined the specifications to address the assembly risks.
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Continual Improvement with Design of Experiments

A client transferred a tool for a long component with a tolerance of 0.1%.
Challenge
The mold had been designed and build without considering part shrinkage.
Solution and Results
The Natech engineers were able to employ a design of experiments to adjust the process rather than adjust the mold.
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Mold Design for Scalability

Industrial Consumer Product
Challenge
Size and feature variations to the part would require eleven separate molds.
Solution and Results
Integrating flexibility into the mold design helped the client avoid the costs associated with building a new mold for each variation.
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Quality by Design: Mold Design

Diagnostics
Challenge
Improve the mold design to improve quality and extend mold life
Solution and Results
Improved process control, wider processing window, and reduced cycle time
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