Cases
Case studies
Client names withheld — process and outcome summaries. Detail under NDA.
2sample paths
Anonymousno names
T0approved path
NDAdetail available
01 · Automotive
Trim clip — 4-cavity cold runner
ABS trim clip. ~80k/yr. DFM 3 days → tool ~5 weeks → T0 in 2 loops.
- Draft & ejection locked in DFM
- Cold runner (scrap OK)
- T0: 3 critical dims + surface
- Process card for production lots
02 · Technical housing
PA+GF connector body + insert
PA6 GF30 body, brass insert. Low volume, tight dims. FDM assembly 4 days → tool ~6 weeks.
- FDM assembly trial first
- CNC insert pocket + EDM detail
- Cooling revise for warpage
- Small lots after approved T0
03 · White goods
Lid hinge — hot runner 2-cavity
PP lid hinge. Visible A-side. Hot runner cut scrap; cycle ~28 s.
- Gate vestige on A-side managed
- Hot runner balance
- Textured insert swap
- Color stability in production
04 · Electronics
Enclosure — snap-fit + PCB nest
ABS/PC enclosure. Snap-fit and PCB supports validated in DFM; T0 with assembly jig.
- Snap-fit draft + shrinkage
- PCB nest tolerance
- FDM assembly jig
- 2k trial lot after T0
05 · Device housing
Non-sterile device shell
PC shell, low volume. FDM form first, then single-cavity tool; surface Ra target defined.
- Form check via FDM
- Single-cavity pilot tool
- Flash / surface control
- Documentation pack
06 · Packaging aid
Clip / retainer — multi-cavity cold
PP clip, high volume. 8-cavity balanced cold runner; ~120 t class.
- Cavity balance + cooling
- Ejector marks off show face
- SPC dims per lot
- Tool maintenance plan
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