Below are small plastic parts and assemblies for injection molding I designed and/or improved upon. Each one resulted in updated tolerances and dimensions I recorded in CAD drawings with updated GD&T, which I have left out for intellectual property reasons. All of these components were designed for manufacturing in high volumes, >10k.
Redesigned injection molded part for DFM improvements. Part was a shipping stop block designed to be clamped down under load. Added a orientation feature to prevent block from being inserted backwards and designed feature to be molded with an insert. Added several new features designed to reduce warp and brittle fracture failures.
Polypropylene part that is welded to a flat polypropylene surface. Added a border around the rim of the part. This allows the laser welded part (left) to be ultrasonically welded instead (right) with a collapse region around the same footprint. This part is designed to create a seal under pressure and direct flow. Accepted as a design change after implementing a pressurized weld check during manufacturing.
Simple flow test coupon for manufacturing team to conduct batch testing. The left boss feature is an inlet for a tube to be press fit to supply air pressure. The right feature is a cavity for inserting a spun plastic plug to test and reject plugs with resistances that are too high. A channel with rounded edges connects the two. Is to be sealed off with adhesive backing. Resistances calculated using Ohm's Law.
