PrintIn a recent LinkedIn Live, Alex Anderson and Lee Rafdal discussed critical insights into micro-injection molding, addressing listener questions and sharing expertise on design for manufacturability (DFM) and design for micro molding (DFMM). The discussion highlighted Accumold’s industry-leading position as a micro-injection molding specialist based in Ankeny, Iowa, emphasizing their unique capabilities in manufacturing miniature, precise components for medical devices and other high-tech applications.
The conversation underscored the importance of early-stage collaboration in the product development cycle. Alex Anderson highlighted that early engagement in DFMM significantly accelerates project timelines by preventing costly revisions later on. “Providing DFMM early in the process, especially for some of these higher priority projects that our customers have, really helps us save total time when we’re looking at the timeline from kind of a zoomed out view,” said Anderson.
Both engineers emphasized that micro molding isn’t limited strictly to small-sized components but also includes larger parts with micro features or extremely precise tolerances. Rafdal explained the subtle distinctions: “DFMM, you know, it’s just micro molding. So that’s not necessarily just micro-sized components. It can be a little larger component with micro features as well.”
Topic Previews
The following topics were discussed in the full show. Be sure to listen to the discussion.
Understanding DFMM and Its Applications
The panel discussed practical applications of DFMM, highlighting a project where collaboration reduced several design options to one viable approach. Anderson noted, “We were able to filter those five or six opportunities down to one or two to be able to move forward with.”
Effective Communication for DFMM
Communication was emphasized as essential for effective DFMM. Rafdal emphasized the importance of clear initial documentation: “Making sure we have a model and drawing if that’s available to review… the model is the most important thing for us.”
Ideal Customer Preparedness
The engineers recommended that customers prepare detailed models and assembly files to facilitate clear and productive discussions. Rafdal noted, “Knowing which of those features are critical for the fit of the assembly is important… It just helps us make those decisions based on the actual assembly.”
Challenges and Limitations
The panel addressed challenges in micro molding, particularly focusing on thin-wall molding constraints and material selection. Rafdal warned, “Thin wall molding, there is a point where there is too thin, right? The material also makes a big difference.”
Material Selection Challenges
Material selection emerged as a recurring theme, underscoring its critical role in manufacturability. Anderson cautioned listeners, “Not all materials mold the same and you may not be able to achieve each design in every material.”
Effective Communication of DFMM
The panel emphasized the use of digital tools and face-to-face meetings to streamline DFMM communication. Rafdal described the effectiveness of quick visual exchanges, saying, “Screenshots are a great quick way to send them something… real simple.”
The discussion provided valuable insights, emphasizing collaborative communication between customers and Accumold’s technical teams to ensure successful outcomes in micromolding projects.