Design for Manufacturability (DFM) with Design and Prototype Companies

Design and Prototype Companies

Design for Manufacturability (DFM) with Design and Prototype Companies

Design for Manufacturability (DFM) with design and prototype companies is a crucial aspect of product development that focuses on designing products that are easy and cost-effective to manufacture. By considering the manufacturing process early on in the design phase, DFM can help to ensure that a product can be manufactured quickly, efficiently, and at a lower cost. Here are some of the reasons why DFM is so important:

1. Cost Reduction:

DFM can help to reduce the cost of production by identifying and addressing manufacturing challenges before they become problems. By designing products with manufacturing in mind, with design and prototype companies’ engineers can minimize the use of materials, simplify assembly processes, and reduce the number of parts needed, all of which can result in significant cost savings.

2. Improved Quality:

DFM can help to improve the quality of a product by ensuring that the manufacturing process is optimized for efficiency and accuracy. By designing products that are easy to manufacture, engineers can minimize the number of defects and reduce the likelihood of errors, leading to higher quality products.

3. Faster Time to Market for Design and Prototype Companies:

DFM can help to speed up the time to market by reducing the time it takes to manufacture a product. By designing products that are easy to manufacture, engineers can reduce the time required for production and testing, allowing products to be brought to market faster.

4. Increased Flexibility:

DFM can help to increase the flexibility of the manufacturing process. By designing products that are easy to manufacture, engineers can quickly and easily make changes to the manufacturing process without having to make major modifications to the product design.

5. Enhanced Sustainability:

DFM can help to enhance sustainability by reducing the waste generated during the manufacturing process. By designing products that are easy to manufacture, engineers can minimize the use of materials and reduce the amount of waste generated, helping to create a more sustainable manufacturing process.

6. Improved Customer Satisfaction:

DFM can help to improve customer satisfaction by ensuring that products are manufactured to the highest quality standards. By designing products that are easy to manufacture, engineers can reduce the number of defects and improve the overall quality of the product, leading to increased customer satisfaction.

In conclusion, DFM is a critical aspect of product development that can help to reduce costs, improve quality, speed up time to market, increase flexibility, enhance sustainability, and improve customer satisfaction. By considering the manufacturing process during the design phase, engineers can create products that are both functional and cost-effective to manufacture, helping to ensure their success in the marketplace. With the help of design and prototype companies such as Auell Consulting we can help to ensure your design is ready for manufacture before going to production to optimize you end product.  Learn more about how we can help with DFM on your design.


Design and Prototype Companies

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Conducting Market Research for Consumer Product Development Companies

Consumer Product Development Companies

Conducting Market Research for Consumer Product Development Companies

Market research is an essential component of new product development for consumer product development companies and innovators. It involves gathering and analyzing data about target consumers, competitors, and the market to gain insights into the potential success of a new product. Without market research, a new product launch could be based on assumptions rather than actual data, increasing the risk of failure. Here are a few reasons why market research is so important for a new product:

Consumer Insights

Market research provides valuable insights into the needs, preferences, and behaviors of target consumers. By understanding these factors, consumer product development companies can tailor their product offerings to meet the needs of their target market, increasing the chances of success.

Competitive Analysis

Market research helps companies understand their competition and identify potential opportunities and threats in the market. By analyzing the competition, companies can gain a better understanding of what products are already available and what differentiates them from the competition.

Market Trends

Market research provides insights into current and future market trends, allowing companies to identify potential opportunities and challenges. By staying informed about market trends, companies can make informed decisions about product development, marketing, and sales.

Product Feasibility

Market research helps companies determine the feasibility of a new product by gauging the demand for the product and the willingness of consumers to pay for it. By understanding the potential for success, companies can make informed decisions about the development and launch of a new product.

Better Product Design

Market research helps companies design better products by providing valuable insights into the needs and preferences of target consumers. By considering consumer feedback, companies can design products that meet the needs and expectations of their target market, increasing the chances of success.

Increased Profitability for Consumer Product Development Companies and Innovators

Market research can lead to increased profitability by reducing the risk of product failure. By understanding the market and consumer needs, companies can make informed decisions about product development, marketing, and sales, increasing the chances of success and profitability.

Market research is a crucial component of new product development for consumer product development companies. It provides valuable insights into the target market, competition, and market trends, allowing companies to make informed decisions about product design, marketing, and sales. By conducting market research, companies can increase their chances of success and profitability and reduce the risk of product failure.

Learn about Denver Product Design’s product development services and how we can help you launch your new product here.

Consumer Product Development Companies

New Product Launch of the ForkLocker

New Product Launch

New Product Launch of the ForkLocker

Dirt biking is an exhilarating sport that requires skill, control, and precision. Whether you’re a professional rider or a recreational enthusiast, you know that getting off to a good start is crucial for success. One tool that can help you achieve a better start is a holeshot device.  Auell Consulting, a product design company, has worked with Rackum Racing to develop the ForkLocker an innovative and extremely effective holeshot device that is just launching into the market.

So far the ForkLocker new product launch has received enthusiastic response from professional and recreational riders alike. Some of the professional dirt biking racers who are utilizing the device are the entire Partzilla and PRMX team and the esteemed Deven Raper from team NextLevel.

The Fork Locker is a mechanical device that is mounted to the front forks of a dirt bike. It works by compressing the front forks and holding them down until the rider releases the device. This results in a more controlled launch off the starting line and can provide a significant advantage over other riders.

New Product Launch rackum racing

Here are some of the benefits of using the ForkLocker’s new product launch:

  1. Faster starts: The most obvious benefit of the ForkLocker holeshot device is that it allows you to get off the line faster. By holding down the front forks and compressing the suspension, the device keeps the front wheel on the ground and prevents it from lifting up, which can cause a loss of traction and slow you down.
  2. Locked out by a single person: The advantage of the ForkLocker over competitive products is this device can be used by a single person, while other holeshot devices on the market require two people to lock out the shock of a dirt bike. This is an incredible advantage to the dirt bike rider.
  3. Better control: The Fork Locker holeshot device also gives you better control over the bike during the launch. By keeping the front wheel on the ground, you can steer the bike more accurately and avoid collisions with other riders.
  4. Increased confidence: Knowing that you have a tool that can help you get a better start can increase your confidence on the starting line. This can help you stay focused and perform at your best, which can lead to better results.
  5. Consistency: Using a holeshot device can also help you achieve more consistent starts. By taking out the variable of how well you can control your bike at the start, you can focus on other aspects of the race, such as timing and positioning.
  6. Reduced fatigue: A good start can also help you conserve energy and reduce fatigue. By getting out in front of the pack early, you can avoid getting caught up in traffic and having to work harder to make up ground.

Auell Consulting a product design company worked on many aspects of this project in tandem with Rackum Racing including product design, prototyping, packaging design, logo design, manufacturing support and product sourcing.  Learn more about how we can help you with your next project by exploring our product design services.

The new product launch of the Fork Locker hole shot device is a valuable tool for any dirt bike rider who wants to improve their starts and gain a competitive advantage. By providing better control, increased confidence, consistency, and reduced fatigue, the ForkLocker can help you achieve your best performance on the track. Whether you’re a professional racer or a weekend warrior, consider adding a ForkLocker to your dirt bike setup to improve your racing results!  Learn more about their products by visiting Rackum Racing’s website.

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New Product Idea and Product Designing Companies

New Product Idea and Product Designing Companies

New Product Idea and Product Designing Companies

Developing a new product idea can be a challenging and exciting process. Many people ask, “How do I come up with a great new product idea?”  With the right approach and tools, anyone can generate new product ideas that have the potential to make a real impact in the market. Many of our clients come to us having already identified what their new product idea is, but here are a few steps that can help you come up with a new product idea.  Once you’ve come up an idea the next step will be identifying product designing companies.

Identify a Problem

Start by identifying a problem that you or others face. This could be anything from a daily inconvenience to a major issue affecting a particular industry. Once you have identified the problem, consider how you could solve it with a new product.

Conduct Market Research

Research the market to see if there are any existing solutions to the problem you have identified. Look at what products are already available and what they offer, and consider whether there is room for improvement.

Gather Feedback for your New Product Idea

Talk to people who have experienced the problem you are trying to solve. Ask them what they would want in a product that solves their problem, and gather as much feedback as possible. This can help you gain a better understanding of the market and what potential customers are looking for.

Look for Inspiration

Look for inspiration for a new product idea in unexpected places. Attend trade shows, read industry publications, and scan social media for trends and innovations in related fields. Sometimes, the best ideas come from seemingly unrelated industries or products.

Think Outside the Box

Don’t be afraid to think outside the box. Consider unconventional solutions, and don’t be discouraged if your ideas seem a little crazy at first. Sometimes, the most innovative and successful products are the ones that challenge conventional wisdom.

Brainstorm and Refine

Once you have generated a list of potential product ideas, it’s time to brainstorm and refine. Work with a team or bounce your ideas off trusted friends and family to get feedback and make improvements.

Test, Validate, and Product Designing Companies

Once you have a product concept, it’s time to test and validate it. This could involve creating prototypes, conducting surveys, or talking to potential customers. The goal is to ensure that your product idea is viable and has the potential to succeed in the market.

This is where identifying product designing companies can be beneficial.  Denver Product Design specializes in this step and can help you along the path to design, prototyping and testing.  Our clients have come to us with anything as simple as a napkin sketch up to any step along the product development process.  We’re happy to get involved during any of the phases of the product development process.

Coming up with a new product idea requires a combination of research, creativity, and iteration. By following these steps, you can develop a product concept that has the potential to solve a real problem and succeed in the market. Remember to be persistent and stay focused, and don’t be afraid to take risks and think outside the box.

To learn more about how we can help with the next steps of the product development process and our services, click here.

Black Phosphorus Product Development and Manufacturing Innovation

Black Phosphorus an Innovation in Product Development and Manufacturing

Black Phosphorus Product Development and Manufacturing
Product development and manufacturing is constantly driven by the pursuit of new and innovative materials that can improve the performance, durability, and sustainability of products. One of the most exciting recent developments in this field is a new material called black phosphorus, BP, which has emerged as a promising alternative to graphene.
Black phosphorus, also known as BP, is a two-dimensional material with a unique set of properties that make it highly suitable for a wide range of applications. Unlike graphene, which is a single layer of carbon atoms, BP is made up of multiple layers of phosphorus atoms arranged in a crystal lattice structure.

Electronic Properties

One of the key advantages of black phosphorus is its exceptional electronic properties. It has a high electron mobility, meaning that electrons can move through the material quickly and easily, making it ideal for use in electronic devices such as transistors, field-effect transistors (FETs), and photodetectors. BP also has a direct bandgap, which makes it more suitable for use in optoelectronic applications, such as photovoltaics and LED displays.

Thermal Stability for Product Development and Manufacturing

In addition to its electronic properties, black phosphorus also has a high thermal stability, making it resistant to degradation even at high temperatures. This makes it ideal for use in high-temperature environments, such as in aerospace and automotive applications.
Biocompatability and Biodegradable Electronics
Another important advantage of black phosphorus is its biocompatibility, which makes it suitable for use in medical and biological applications. For example, BP can be used to make nanoscale sensors that can detect changes in biological systems, such as the presence of toxins or pathogens. It can also be used to make biodegradable electronics that dissolve in the body, reducing the risk of complications and long-term harm to patients.

Manufacturing Challenges

Despite its many advantages, the development of black phosphorus as a commercial material is still in its early stages. There are several challenges that need to be addressed, such as scaling up production and improving the quality and consistency of the material. However, with the increasing demand for high-performance, sustainable materials in product development and manufacturing, black phosphorus is poised to play a significant role in shaping the future of the industry.

In conclusion, black phosphorus is a new and exciting material that is set to revolutionize product development and manufacturing. With its exceptional electronic, thermal, and biocompatible properties, BP offers a range of potential applications in fields as diverse as electronics, aerospace, biomedicine, and more. As research and development in this area continues to advance, the full potential of black phosphorus will likely be realized, making it a key player in shaping the future of sustainable, high-performance products

Product Development and Manufacturing

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Graphene, the New Miracle Material in Product Development!

graphene product development

Graphene, the New Miracle Material in Product Development

Graphene is a material that has been making waves in the product development industry due to its remarkable properties. It is a single layer of carbon atoms arranged in a hexagonal lattice, making it incredibly strong and lightweight. The material was first isolated in 2004 and since then, researchers have been exploring its potential for various applications.

Graphine Material Properties

Graphene’s unique combination of strength, flexibility, and electrical conductivity make it a versatile material for product development. It is estimated that graphene is around 200 times stronger than steel and is also an excellent conductor of heat and electricity. This makes it ideal for use in products that require strength and conductivity, such as electronics and batteries.


In electronics, graphene can be used to produce thinner, lighter, and more flexible displays, as well as faster and more efficient transistors. This can lead to the development of smaller, more powerful devices that consume less energy. Additionally, graphene’s high electrical conductivity makes it ideal for use in batteries, where it can improve energy storage capacity and reduce charging time.

Product Development in Polymers

Graphene is also being explored as a material for use in new composite materials, such as graphene-reinforced polymers. These composites can offer improved strength and electrical conductivity compared to traditional composites, making them ideal for use in various applications, including aerospace, construction, and sports equipment.  This is an ahead of our consumer based goods industry, where we see lots of interesting potential application of this material.

Water Filtration

Another exciting application of graphene is in the field of water filtration. Researchers have found that graphene oxide membranes can filter out even the smallest impurities from water, making it a promising material for use in water purification systems. This could have a significant impact on global water security, as it could provide access to clean drinking water in areas that currently lack it.

Graphene is a remarkable material with the potential to revolutionize the product development industry. Its combination of strength, flexibility, and electrical conductivity make it ideal for use in a wide range of applications, from electronics and batteries to water filtration and composite materials. The future of graphene in product development is exciting, and we can expect to see many new products and technologies emerge in the coming years as research continues to advance.

There are so many options of how to leverage this new materiel in new product development.

Denver Startup Week Product Design and Development Company

Product Design and Development Company

Denver Startup Week Product Design and Development Company

Denver Startup week started on September 20th and featured a wide range of presenters including Patrick Auell as a product design and development company expert as well as venture capitalists, business owners and founders, branding experts, marketing experts, a Denver creative agency, global visitors, design experts, and experts on intellectual property.  It was an incredible week of collaborative learning, sharing and growing.

Fellow Presenters Denver Creative Agency

We had the opportunity to present on the topic of “From concept to product to success”.  Presenting with us was Fransis from Mi Casa a resource center who had an amazing depth of knowledge on resources available to new businesses and founders, an individual who runs a manufacturing facility in China, Luke Tierney who is an expert on marketing and works as a Denver creative agency like Auell Consulting, and a founder of a local business who has moved from a startup through a medium sized company.  We found that the group of us had many synergies and different insights along the path of product design and development.  We feel that expanding our network of related industry experts helps us belter serve and help our clients to be able to guide them towards resources that can assist them along the product development path.

Learning Opportunities

We also attended a variety of presentations from other industry experts as a way to grow and continue to connect within the industry as a product design and development company.  One of the most intriguing days for me as a business founder and because we work with a large number of other business founders was the venture capital presentations.  There were local venture capital groups that aim at helping fund startup companies and growing companies to help them grow quickly and have capital to assist in this growth.  The discussions included how to connect with these venture capital networks as there are a large variety of them in Colorado looking to connect with entrepreneurs.  They also shed light on how to present a pitch and even had the opportunity to speak with quite a few of them in person.  As a product design and development company we found this to have an immense amount of information that would be relevant to our clients.

Denver Startup Week is an annual event in Denver that is free for anyone who has a desire to learn and grow as an entrepreneur and business and we highly recommend attending to all fellow business owners and inventors.

Denver creative agency

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Denver’s Best Prototyping Companies Present

Denver’s Best Prototyping Companies Present at Denver Start Up Week

From Concept to Product to Success by Best Prototyping Companies

Best prototype compaines in the US

Denver Start Up Week is an exciting event for entrepreneurs and the best prototyping companies in Denver.  It’s a community building event for everyone in Denver’s thriving entrepreneurial ecosystem.  There will be showcases of the best in innovation and the latest developments in the industry.   There’s a wide range of panelists that will be attending and presenting relevant information for any inventor or company that is launching a new product.  Denver Product Design’s team has been asked to present as one of Denver’s best prototyping companies during a panel presentation that is called “From Concept to Product to Success.”  Since we are helping bring our clients through all these stages of the design process we will be spreading our knowledge and advice on the keys to success in your business development, product development, and project launch.

The panel we will be speaking at is on Thursday September 22 at 10am.   Visit this link to read more of the details on “From Concept to Product to Success”.  We’d love to see you there!

Having a fabulous product idea gets you about 10% of the way to a successful business.  There are many steps along the road of product development.  Our panel will offer a discussion on many hurdles that are faced through prototyping, product design, manufacturing, sourcing, and sales launch of a new product.  This panel as well as the rest of Denver Startup Week will offer an incredible wealth of information for anyone wanting to start a new business.  We have attended in years past and presented previously as well.  There are always great connections that can be made with people in the product development industry and people looking to have their products developed.  Stop by our presentation to listen.

Learn more about the product design process by clicking on the icon below.

Best Prototype Companies in the US

Award Winning Innovation

Denver Product Design Firm and Client’s Award Winning Innovation

The Click it Stick’s award winning innovation is a patented innovative product developed by a 70 year old grandfather with the help of Auell Consulting won two prestigious awards shortly after its release into the market. This award winning Innovation has been awarded multiple awards for travel safety and car safety.

The first award it won is the 2020 Product of the Year Award in Travel Safety as voted by parents and educators at Creative Child.  It is an honor and great privilege that a design that we were involved in was awarded with this.

The second award that was received was the 2020 Top Choice of the Year Award Car Safety.  Baby Maternity magazine bestowed this award on the click it stick as voted by moms and moms-to-be.

Award Winning Innovation

Award Winning Innovation 2020 Product of the Year Award in Travel Safety

The Click it Stick makes it a quick and easy process to switch a car seat from one car to another.  This innovative product has made it easier for moms, dads, grandparents and other child car provides to move a car seat from one car to another.   Previously the installer of a car seat would have to thread the car seat strap through the back of a car seat.  This process could easily scrape up the installers hand and arm.  With this tool a magnet can be attached to the buckle and the seat belt can quickly, easily and safely be threaded through the back of the seat without a problem.

Auell Consulting a product design firm helped in the development of this product from concept to consumer.

Award Winning Innovation Product Design Firm

Click it Stick Developed by Client and Product Design Firm


To learn more about our product design firm and our award winning innovation visit our featured projects page!



Auell Consulting listed by DesignRush as top Creative Agencies to Hire in 2022

Auell Consulting Listed as Top Creative Agencies to Hire in 2022 a Product Prototype Company

Auell Consulting a product prototype company had an exciting mention in a press release today being listed by DesignRush as one of 44 “Top Creative Agencies to Hire in 2022”.  They have a extensive marketplace connecting businesses with agencies.  They featured experts in product design, branding, graphic design, logo design, and packaging design.  Auell Consulting has been working with DesignRush for the last several years and we have been impressed with the number of hits and clicks we’ve received with them.  It has motivated us to up our game as one of Denver’s Top Creative Agencies and also to ensure we are providing our clients with the best in class product design services including: product design, packaging design, logo design, product branding, and working as a product prototype company.  We look forward to continuing to sever our clients helping them to bring their concepts to consumer.

Learn more about our product design, engineering and design services here!  We offer a whole host of different design services to help along every step of the product design process.  Starting from concept development and brainstorming creative solutions, industrial design, 3D CAD modeling, detailed engineering design, design for manufacturing with DFM reviews, logo design, packaging design, branding, website design, sourcing, manufacturing support, sourcing, and importation support.  With all these services we can be your one shop stop for product development.

Top Creative Agencies 2022 Denver Product Prototype Company

Top Creative Agencies Award

See the press release here!

Top Creative Agencies 2022 Denver Product Prototype Company 2

Denver Product Design Selected as Top Product Design Company

Top Product Design Company Denver Product Design Award

Denver Product Design Selected as Top Product Design Company

We have an exciting announcement to make.  Auell Consulting – Denver Product Design has been selected by DesignRush as “Top Product Design Company”.  After 12 years of business and countless product development projects it is exciting to receive this recognition.  Our team of engineers, industrial designers,  graphic designers, marketers and sourcing staff are thrilled to receive this distinction.

“It’s so great to have a local Colorado small business like our receive this recognition of Top Product Design Company and such and honor that they approached us to tell us we’d been selected,” said Denver Product Design’s marketing director Melissa Auell.  “We look forward to many more exciting years helping people make their product development dreams a reality.  We are very grateful for this award.  It is an fabulous morale-booster that will encourage all of our team to continue doing our best work.”

Design Rush just informed of us of this very thrilling news today.  They shared that they will be publishing a press release to announce this award with top news agencies like Yahoo Finance, ABC, NBC and other global media outlets.  DesignRush recognizes professional agencies and will be featuring Auell Consulting – Denver Product Design in their industry-focused press release for Top Product Design Companies.  The expected publish date of their article and announcement is March 10th, 2021.  We will share another post once the press release has been published.  To see our Top Product Design Company listing on their website, click on Top Product Design Company.

Design Rush is also publishing an article on the Top 25 Business Consulting Firms, we are scheduled to be included in this article as well.  To read their article visit their articles website:  Best PEO Companies.

Top Product Design Company Denver Product Design

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WTS Kicks Off Launch for Drum Tuning r[E]volution

Product Innovation WTS Denver Product Design Drum Tuning

Denver Product Innovation

WTS Kicks Off Launch for Drum Tuning r[E]volution

Denver, Colorado – Welch Tuning Systems (WTS) tomorrow is releasing the WTS Artistry Series Drum line, featuring the revolutionary Welch Tuning ­­System. ­ A unique product innovation that allows you to tune a drum in 5 seconds or your whole kit in 30 seconds!  This market shaking drum tuning patented product invention is hitting the market now. With the turn of a knob you can even change the pitch of your drums mid-performance.  “I’ve seriously never seen anything that’s so revolutionary…It’s so easy it’s unbelievable.  Take the drums out…and within minutes the whole kit is tuned up and sounds great…” says Chris Sheldon, Professional drummer.


How does this product innovation work?

Each WTS Artistry Series drum features a series of self-adjusting pulleys that allow tension to equalize around the whole drum.  This results in beautifully tuned drums at any pitch.  Since the pulleys are mounted to the drum hoops, this means there is significantly less hardware in contact with the shell and up to 90% less holes drilled in the shell. This allows the drum shells to breathe and resonate to their full potential. There’s only one point of adjustment so it locks the tension for the entire drum.  Now there’s no more tension rods loosening while you play! “After 3 years and countless hours of perfecting this tuning system, I’m so excited to finally be able to launch the Welch Tuning System,” said Patrick Auell, co-founder of Welch Tuning Systems and CEO of Auell Consulting – Denver Product Design. “It’s going to change the drumming world and changing the pitch of a drum mid performance will even open up possibilities of new drumming styles developing.”



The revolutionary product innovation is hitting the market though a Kickstarter crowd funding campaign. The campaign is launching during the NAMM (National Association of Music) conference in Anaheim, CA, January 24-27, 2019.  Wre WTS will have a booth set up to demo one of the first WTS Artistry Series Drum sets.  They are offering the first drums off the production line at a deep discount for a limited time through the Kickstarter.  You can be the first to own your own set of revolutionary WTS Artistry Series Drums and a piece of history in the making.

4 Step Injection Molding Design Guide

Injection molding is a manufacturing process used widely across many industries to create plastic consumer products.  It is used for a wide variety of different products such as bottles, combs, packaging, children’s toys, gardening implements, and much more.  This three part injection molding design guide will help to provide a firm understanding of plastic injection molding basics.

The process of injection molding is fascinating, first plastic granules are loaded in a hopper.  They are heated, mixed and fed through a screw conveyor at a high temperature and pressure into your mold (tool) cavity through a runner system.  The runner system distributes the molten plastic into the mold so that it evenly fills the mold cavity.  The plastic cools and shrinks.  Once the product is cool, ejection pins push your part out of the mold.

In this injection molding design guide, we will discuss how part geometry plays a large role in the quality of the end product.  There are many possible defects that can happen during this process.  To minimize these defects, we have compiled a 3 part article to serve as a plastic part design guide.  In this first section of the article we will discuss plastic part geometry design guidelines.

1. Wall Thickness

It is ideal to have a uniform wall thickness. Thick sections of a part can shrink unevenly during the cooling process creating defects such as sink marks, voids, warping, and stresses. The maximum recommended thickness varies for different materials but generally should be in the 2 to 4 mm range. Having a consistent wall thickness can help to avoid these common injection molding defects.

If there is no way to make you part with a uniform wall thickness, then as gradual as possible transition should be used.

injection molding design guide draft for plastic part design

2. Draft

Draft is the angle off of parallel from the part’s wall to the direction the mold opens. This is required for injection molded parts so that the part can be removed or released from the mold. Typically a draft angle of 1 to 2 degrees will work with most situations, while a heavily textured surface could require as much as a 5 degree draft.


3. Radius

Radii should be added to all corners of parts. Avoiding sharp corners reduces stress points in your part and allows the molten plastic to fill the mold more evenly.

  1. The radius on the inner side of the part should be at least half the of the wall thickness. Ri= ½*T
  2. The radius on the outside of the part should be the part thickness plus the inside radius. Ro=3/2*T
  3. The radius on rib or boss should be a quarter of the part thickness.


4. Ribs

Ribs are used to create a more rigid part and increase loading capacity. If you desire to increase your parts rigidity and strength, the quantity of ribs should be increased rather than increasing ribs thickness or height.

  1. Thickness of ribs should be 40-60% the wall thickness.
  2. Rib spacing should be at least two times the wall thickness apart.
  3. Rib height should be limited to three times the wall thickness


Read part 2 of our injection molding design guide.