Case Study: DFM Improvement in Roving Guide (8-Cavity Mold)

Problem Statement:

During the Design for Manufacturing (DFM) review of Roving Guide 8-cavity injection mold, an issue was identified in the side core extraction area. While extracting side core, feather edge (sharp edge) noticed in the side core as indicated in the image

Root Cause Analysis:

 Because of the R5 radius of the part at the side core region, a knife edge was formed due to a thin and weak edge, causing the design to be unsuitable for smooth side core extraction.

Solution Implemented:

The radius at the side core extraction area was reduced from R5 to R1.5. This design change provided a controlled and smooth transition of material, eliminating the formation of sharp feather edges during side core design.

Results:

• Feather edge completely eliminated

• Smooth side core extraction achieved

• Improved surface finish and part strength

• Reduced risk of wear and part rejection

Conclusion:

• This case study demonstrates how a small design modification based on DFM principles can significantly improve part quality and mold performance. Optimizing the radius from R5 to R1.5 ensured reliable side core extraction, reduced defects, and enhanced production efficiency.Improved manufacturability for 8-cavity production