DFM Rules Accounting for the IM Process:
● Draft angle of 2-5 degrees included on the side of text (4 degrees used).
● Text height kept to 0.4 mm.
● The interior radius should be at least half of the wall thickness (2 mm used for interior fillets).
● The exterior radius should be the inside radius plus the wall thickness (2 mm + the 4mm wall thickness = 6mm used for exterior fillets).
● No side action.
● No sharp corners (always fillet).
● Even thickness (consistent thickness of 4mm throughout).
Varying Considerations:
- Tonnage Required for Single Cavity vs. Double Cavity and ABS vs. PC:
Single Cavity ABS would require 176 T and Single Cavity PC would require 205 T, whereas double cavity ABS would require 352 T and double cavity PC would require 410 T
- Cooling Time:
The cooling time for the product manufactured with ABS would be 57.04 seconds and the cooling time for PC would be 56.30 seconds. Not a significant difference for small scale manufacturing.
- Cost of the Parts:
Manufactured through ABS, product would be priced at $1.80 vs the cost of the product in PC, which is $2.63
**Calculations do not take into consideration defect rate (100% perfection assumed) or material markup (including costs such as storage of material)
