At Unimold Asia, we guide our clients through every stage of product development, from prototyping to full-scale industrialization. Here’s a case study illustrating our rigorous approach and technical expertise.
Step 1: DFM Analysis and Prototyping
The project began with a DFM (Design for Manufacturing) analysis of the parts. We thoroughly reviewed the draft angles, wall thicknesses, and identified potential issues that could affect mold design. This step is crucial for ensuring optimized and reliable manufacturing.
For the prototyping phase, we relied on our sister company Protolis to produce 5 sets of vacuum cast parts. This method uses a silicone mold filled with polyurethane resin under low pressure, simulating the mechanical properties of the final injected part.
Unlike 3D printing, vacuum casting offers parts with a flexibility modulus much closer to the final product. This enabled our client to:
- Refine the 3D design of clip areas
- Validate rib stiffness
- Internally test the parts with their teams and clients
- Confirm the relevance of this new part before moving to production
Step 2: Injection Mold Manufacturing and Qualification
Once the prototype was validated, we proceeded with the injection mold manufacturing—our core historical expertise. This step included:
- Rheological studies
With 4+4 parts of different versions and volumes, we worked with the hot runner supplier to improve cavity balance and reduce deformation.
- Mold design and engineering
Weekly tracked machining of components
- Testing and fine-tuning
Detailed reports ensured the parts met customer expectations - Modifications
Quick and cost-effective geometry changes, including added ribs and revised clip areas
- Material testing
We optimized a blend of fiber-reinforced polypropylene and high-density polyethylene (HDPE) to ensure mechanical strength without brittleness—especially critical for outdoor use and freezing conditions.
The goal was to validate tooling based on two key criteria:
- An optimized cycle time
- Controlled deformation
Due to the length of the part, warping was a major issue. We spent considerable time fine-tuning the material mix, cycle time, and injection parameters to ensure excellent stability.
Step 3: Automation of Metal Insert Overmolding
Alongside mold development, we worked on process automation, as each part required a metal insert to be integrated during injection. We developed a custom automated solution including:
- An insert feeder located near the mold
- A loading bin capable of several hours of production
- A vibrating blade-based distribution system for precise insert placement
After multiple trials and adjustments, we successfully optimized insert overmolding automation, ensuring smooth, efficient, and repeatable production.
Conclusion: A Successfully Industrialized Project
Nearly a year of work, over 15 tests, countless email and phone exchanges… But in the end, a fully satisfied client! Just a few hours after receiving the mold, production was up and running.
At Unimold Asia, we leverage our expertise and advanced technologies to ensure a smooth, well-managed transition from prototyping to industrialization.
Got a similar project? Contact us to discuss how we can help!