The product required a liquid silver spray paint. If not filled well, the subsequent spraying process would require multiple touch up repair steps which would be time consuming and the appearance of the product would ultimately suffer.

The normal mold-making method is to open up a feed port on the side of the product, however, this would result in a larger mold size and eccentricity.

The following represent the problems present in this case early on:

• In production, the mold is not in the middle of the machine, which will easily cause damage to the machine due to uneven force.
• Mold eccentricity tends to cause materials to dislocate from their mold cavity.
• To design a feed port on the side requires manufacturing a special stamping die for removal and increasing production procedure.

On receiving a mold making requisition, our mold design engineer convened with the product engineer and manufacturing unit for discussion on the mold design scheme. Through calculation of the related mold design data, scheme modification, the final calculation result proved that the feed port can be changed to allow a topside opening. On the modified design, the area of the feed port and the feed speed can meet the filling demands of product, while no extra processing would be added. To add further verification on the design, we had made 3D mold design and performed a moldflow analysis. The analysis results coincided with our discussion.

During the mold manufacturing process, our design scheme had been fully confirmed and the final result of mass production coincided with our expectation. From this example, we realized that only with the best optimized design can products manifest the best production efficiency.