Design Tips
- The mold side of a part is controlled and the other side (material side) will vary. This should be taken into consideration when determining whether to use a positive or negative mold.
- Drawings should be dimensioned to the mold side of the part.
- Draft Angles – Larger draft angles produce parts with more consistent wall thicknesses. Typically 2 degrees of draft or more is preferred.
- Radii – For positive molds, the minimum radius should be greater than or equal to the starting thickness of the sheet. For negative molds, the minimum radius should be .030”. Larger radii produce better parts.
- Draw Ratio – Ideally, the draw ratio should be 2 to 1 (twice as wide as high). More severe draw ratios are achievable with special techniques and tooling.
- Texture – Texture can provide a consistent surface appearance and aid in hiding cosmetic flaws. This can be achieved by adding texture to the sheet or the mold.
- Undercuts – Undercuts in parts can be achieved by using specialized tooling with moving components.
- Tolerances – Our process can achieve typical tolerances of +/- .030” to +/-.060”.
- Thermopro has the capability of value added processes such as painting, assembly, labels, and printing.
- Formed-in details are often added to a part to increase stiffness/rigidity.
- Prototyping can be an effective way to test the fit, function, and aesthetics of a part design before committing to production tooling.
Guidelines
- How and where will the part be used?
- Will the part be exposed to temperature extremes, weathering, chemicals, vibration, pressure/loading?
- What are the structural requirements of the part?
- Is the cosmetic appearance of the part critical?
- What is the life expectancy of the part?
- What is the target price?
- What is the estimated annual usage of the part?
- What is the expected life of the project?
- Are there any standards or regulations that must be met (ex. UL or government regulations)?