DFM Optimization for Injection-Molded Medical Device Housing
Summary
MedDevice Corp needed to reduce manufacturing costs for their diagnostic equipment housing while maintaining strict medical device quality standards. Initial design had 45% rejection rates due to warping and dimensional issues.
The Challenge
Initial Need:
MedDevice Corp required DFM optimization for their Model MD-2000 diagnostic equipment housing experiencing 45% rejection rates due to warping, sink marks, and dimensional tolerance failures in high-volume injection molding production.
Pain Points:
Excessive wall thickness variations causing warping and sink marks
Complex geometry requiring expensive multi-slide tooling
Long cycle times of 180 seconds impacting production capacity
FDA compliance requirements for surface finish and cleanability
Our Solution
Our Approach:
Comprehensive redesign with uniform 2.5mm wall thickness, optimized gate placement, integrated snap-fit features to eliminate fasteners, and simplified parting line geometry to reduce tooling complexity while maintaining medical grade surface requirements.
Methodology:
Moldflow analysis using Autodesk Simulation Moldflow, material flow optimization, cooling channel design, and prototype validation with rapid injection molding trials to verify dimensional stability and surface quality requirements.
Final Summary:
Final design achieved 98.7% first-pass yield with 65-second cycle time, 40% tooling cost reduction, and full FDA compliance while improving part strength by 25% through optimized rib design and material distribution.
Execution
Process Description:
Implementation involved P20 steel tooling with conformal cooling channels, automated part handling systems, and in-line quality control with vision inspection for dimensional verification and surface defect detection.
Outcome
Value Comparison:
Rejection rate reduced from 45% to 1.3%, production capacity increased by 175%, tooling costs reduced by $180K, and achieved 22-month ROI while maintaining full regulatory compliance and improving product durability.
Client Testimonial:
"The DFM optimization transformed our production line from a bottleneck to our most efficient process. We've exceeded our capacity targets while dramatically improving quality."
- Manufacturing Director, MedDevice Corp