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DFM Analysis: Front-Loading Quality to Slash Mold Costs and Development Risks

2026-01-20

DFM Analysis: Front-Loading Quality to Slash Mold Costs and Development Risks

I. Core Objectives of DFM Review

-Preventive Assessment: Identifying manufacturing risks during the product design phase.

-Cost Optimization: Reducing expenses related to mold modifications and process adjustments.(Click here to view the cost composition of the molds )

-Efficiency Enhancement: Ensuring mass production stability and yield rates (Target≥95%).

Industry Data：

-Early DFM intervention can reduce development costs by 30%.

-80% of mold issues originate from defects in the design phase.

II. Review Team Composition

Role	Responsibilities	Key input
Product Designer	Explain design intent	3D Models / Engineering Drawings
Mold Engineer	Evaluate mold feasibility	Mold Flow Analysis Reports
Injection Process Engineer	Analyze molding risks	Material Property Data Sheets
Quality Engineer	Define inspection standards	Critical-to-Quality (CTQ) Feature List

III. Ten Core Items of DFM Assessment

1. Wall thickness design

-Standard requirements:

- FAQ:

2. Draft angle

Surface Type	Minimun Draft Angle	Texture Compensation
Appearance	≥1°	+0.5°/VDI rating increased by 1 level
Non-apperance surface	≥0.5°	No compensation
Deep cavity structure	≥2°	Requires special polishing

3. Reinforcing Rib Design

4. Parting line planning

-Optimization principles:

5. Gating System

The first key point is the type of gate: narrow gate, large gate, side gate, hot runner, etc. This is crucial.

The second key point is the location and number of gates, which are analyzed using Moldflow and compared with DOE.

The third key point is the defect assessment of the gate (functional defects and appearance defects). Each type of

gate has certain defects, such as the breakage problem of the point gate and the appearance of the gate mark.

The fourth key point is the removal and processing method of the gate, such as cold punching, hot punching, laser cutting,

ultrasonic gate removal and other processing methods for side gates.

6. Ejection System

-Layout specifications:

7. Shrinkage compensationformula:

Mold core size = Product size × (1 + Material shrinkage rate)

Typical material shrinkage rate:

Material	Shrinkage range
ABS	0.5%-0.7%
PA66	1.2%-2.0%
PP	1.5%-2.5%

8. Assembly structure

-Key points of buckle design:

9. Tolerance Analysis

-Statistical methods:

10. Special process

Craftsmanship	DFM rewuirements
Two-color injection molding	Increase the positioning refrence(±0.05㎜)
In-mold decoration	Reserve space for flim stretching(≥3㎜)
Gas assist	Airway diameter≥twice the wall thickness

IV. DFM review process

Pre-review preparation
Formal Review Meeting
Output and Tracking

V. DFM Inspection Example(Gajes Mold)

Check items	standard	Conform to	Problem description
Minimun wall thickness	≥0.08㎜	Yes No
Draft angle	Appearance surface≥1°	Yes No
Parting line position	Does not pass through the exterior surface	Yes No
Number of gates	The filling pressure must br≤80MPa	Yes No

VI.Solutions to typeical problems

Problem phenomenon	DFM optimization solution	Benefit
Insuffcient strength of weld line	Adjust gate position+increase mold temperature	Strength increased by 40%
Ejection deformation	Increase the number of pins+delay time	The defect rate decreased from 8% to 0.5%
Sink marks are obvious	Reduced adhesive content content+pressure holding optimization	Surface quality reaches Class A

VII.Special requirements of the industry

Automotive Parts
Medical Devices
Electronic Components

VIII. DFM Review Outputs

-Signed DFM report

-Modified 3D data (including version number)

-Mold flow analysis verification documents

-List of Potential Failure Modes (linked to PFMEA)

IX. Summary: What Makes DFM Effective?

Pre-processing: Completed before the drawings are finalized.

-Data-driven: Relying on mold flow analysis and simulation tools.

Standardization: Establish an enterprise DFM knowledge base.

Tool Recommendations :

-Moldflow (Mold flow analysis software

- Geomagic Design X (Reverse Engineering Verification

- DFM Design Specifications for Plastic Parts (Enterprise Edition

Conclusion & Value Proposition

Systematic DFM management can reduce the number of mold modifications by more than 50% and shorten the project cycle by 20%-30%.

At Gajes Mold, we dont just manufacture molds; we engineer success. By integrating advanced tools like Moldflow and our rigorous DFM review process early in your project, we ensure that design risks are eliminated before the steel is cut. Partner with Gajes Mold to transform your design concepts into production-ready reality with maximum efficiency and minimal risk.

office@gajesim.com

WhatsApp:8619198137646

Tel:8619198137646

Gajes Mold Technology Co., Ltd.