DFM Integration for Multi-Material Plastic Assemblies
Summary
PlasticTech Innovations faced assembly challenges with their consumer electronics housing requiring 12 separate components and extensive ultrasonic welding. Assembly time exceeded 8 minutes per unit with 15% failure rate.
The Challenge
Initial Need:
PlasticTech Innovations needed DFM optimization for consumer electronics housing assemblies requiring 12 separate injection-molded components with complex ultrasonic welding processes resulting in 8-minute assembly time and 15% joint failure rates.
Pain Points:
Complex multi-component assembly requiring precise alignment
Ultrasonic welding failures due to material compatibility issues
Long assembly cycle time impacting production throughput
Quality control complexity with multiple joint inspections
Our Solution
Our Approach:
Integrated overmolding design combining rigid ABS structure with TPE sealing elements, living hinge features to eliminate separate components, snap-fit assembly with tactile feedback, and material compatibility optimization for reliable bonding.
Methodology:
Multi-shot molding simulation, material adhesion testing, hinge fatigue analysis, and assembly force optimization using design of experiments methodology to achieve optimal fit and function with simplified manufacturing.
Final Summary:
Final design reduced components from 12 to 3 parts, eliminated welding operations entirely, achieved 45-second assembly time with 99.7% success rate, and improved sealing performance while reducing material costs by 32%.
Execution
Process Description:
Manufacturing utilized multi-material injection molding with sequential injection, automated part handling, integrated quality control with force monitoring, and simplified assembly line with single-operator capability.
Outcome
Value Comparison:
Component count reduced by 75%, assembly time reduced from 8 minutes to 45 seconds, failure rate reduced to 0.3%, and achieved 32% material cost reduction with improved product durability and customer satisfaction ratings.
Client Testimonial:
"The DFM integration approach simplified our entire production process while improving quality and reducing costs. We've achieved our throughput targets with significantly better margins."
- Engineering Manager, PlasticTech Innovations