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Consulting >> Design
Materials M & A Support & Technical Due Diligence
Processing Failure/Reliability Analysis & Testing
Tooling Education, Training & Seminars

Today, designers are challenged with multiple requirements while designing plastic parts. Major emphasis is on economics, functionality, manufacturability, and aesthetic appeal. Some compromise during the design process is inevitable and in some cases trade-offs like these lead to premature failures. The most common mistakes made by designers when working in plastics are related to wall thickness, sharp corners, creep, draft, environmental compatibility, and placement of ribs. Viscoelastic nature of plastics materials as opposed to metals, require designer to pay special attention to creep and stress relaxation data. Plastics parts will deform under load over time depending upon type of material, amount of load, length of time and temperature. Robust product development process that incorporates sound engineering is critical. This can be achieved by incorporating a systematic approach to developing a new product. This logical and scientific approach requires step-by-step progression in a definite order. Designers are cautioned not to skip any of the steps for economics reasons or time constraints.

Proto typing aspect of part design process is often overlooked due to cost and time constraints. Regardless of the medium chosen, prototyping technique generate physical models that act as a primary means of communication between marketing, engineering, tooling, and manufacturing groups. The use of the prototype to describe the function, size, shape, feel, and look of a part inevitably leads to a major productive environment and a higher degree of interaction between the members of the product design team. Equally important is the use of structural analysis tools commonly known as finite element analysis (FEA) and process simulation techniques such as Moldflow® analysis. Computer simulations give designers early indication of the weak areas and potential problems. Addressing these concerns prior to mold construction designers can avoid costly rework and untimely product failures.

At Consultek, we focus on providing product design services from concept to completion. Developing a new product requires a series of prudent product development steps. We have developed Product Development techniques that have proven to be highly effective in bringing quality products to market in a timely manner.

  Conurrent Engineering Concepts
  Design for Manufacturing (DFM)
  Design for Assembly (DFA)
  Finite Element Analysis
  Moldflow Simulation
  Rapid Prototyping
  Reliability Studies
    Weibull Analysis
  Case Studies 1, 2, 3, 4 
  Twelve Steps to Six Sigma - A Systematic Approach to Developing a New Product  
  Designing Plastic Parts - Excerpt  
  Moldflow Analysis 
  Finite Element Analysis (FEA)