Material Selection in Design for Manufacturing

This technical report discusses the critical aspects of material selection within the context of Design for Manufacturing (DFM). It outlines how the choice of materials, specifically injection molding resins, impacts various factors such as mechanical properties, appearance, and performance in the molding environment. The document categorizes materials into amorphous and semi-crystalline types, emphasizing the importance of understanding their properties to avoid common pitfalls in DFM. It highlights that selecting materials based solely on one characteristic, such as strength or aesthetics, can lead to challenges related to flow and tolerances, ultimately affecting the design process. The report also details considerations for part performance, print tolerances, and risk mitigation, particularly in overmold applications. Specific examples, such as the use of ABS and TPE materials in a handle half, illustrate the practical implications of material choices. The report concludes by stressing the need for continuous evaluation of material impact throughout the design process to prevent costly redesigns.