Design Optimisation for Injection Moulding




Efficiency and integrity

Structural integrity can be achieved using less material through the use of ‘ribs’; these features can also double as an aid to prevent part distortion. In short, the use of ribs is an effective way of achieving rigidity and strength while avoiding cross-sectional thickness. In cases where it is impossible to avoid a thick cross-section, ribs may also help to minimize the distortion that can occur.

Extremely complex shapes that must combine thick and thin cross-sections should be reviewed in advance so as to determine dimensional stability and tolerance changes that will occur during and after molding.

The environment the part will be operating in should also be considered.  A part with high loads or stresses on certain sections should be within specification either through good structural support, a thermally resistant polymer or both.

Wall thickness is dictated by multiple inputs to the part. It is helpful to design all part cross-sections as thinly and uniformly as possible.

For rougher surface finishes, larger draft angles should be used.


These are just a few of the principles which can be applied to improve the performance, cost efficiency and structural integrity of plastic parts. A detailed analysis is often necessary to understand the function of your part to direct us down the best route to building an injection mould tool.

If you have any questions just give us a call and we’ll be glad to look at your design in more detail.