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Want to learn how to design undercuts that don’t cause damage to your parts? Check out our article, which offers tips and tricks for DFM with undercuts, examples of when you might need them, and more. Undercuts in injection-molded parts present a host of challenges to designers and manufacturers. In this article, we’ll take a look at the definition of undercuts, their purpose, applications, and tips for designing parts with them.
An undercut is a recession (a concave or indented area) or protrusion (an outward extension or raised area) on a part that prevents or complicates ejection from a mold (demolding).
Generally, designers and manufacturers try to minimize undercuts as much as possible. Some parts, however, need an undercut to function. Let’s take a look at a few of the applications for which an undercut might be necessary.
Threaded parts. You can use undercuts to create parts with threads, so you can incorporate screw-on or twist-on fastening mechanisms into them, such as closures, caps, or connectors.
Interlocking components. Undercuts enable you to design parts with interlocking features that help them fit together very precisely. A good example here is tool design, where the tool’s handle and tool’s head interlock together to ensure that they are stable and aligned.
Sealing mechanisms. If you want to create an effective seal on an injection-molded part – such as those in food packaging or medical devices, which often must be leak-proof or airtight – you’ll probably need to use an undercut.
Clips and fasteners. Parts with clips or fasteners, especially in the form of hooks or tabs, often feature undercuts.
Molded handles. Handles with ergonomic grips are often designed with undercuts.
When creating a part that you know will need an undercut, consider adding one or more of the following features to its design. They allow for additional movement or clearance for the undercut, helping ensure that your part is not damaged when demolding.
Side action cores. Side action cores are inserts that slide in as the mold closes and slide out before it opens. To be effective, however, side action cores must move perpendicularly to the opening direction of the mold, which may pose challenges to a part’s design.
Lifters. Designing parts with lifters is another way to successfully use undercuts. Lifters lift or shift certain features of a part during its ejection from a mold. Like side action cores, they must move perpendicularly to the mold’s opening direction.
Unscrewing mechanisms. Threaded components that rotate – like a bottle cap on a plastic bottle – can help a part with an undercut be more easily released from a mold.
Draft angles. Your parts should have sufficient draft angles to help it be more easily ejected from a mold. A draft angle is a tapered angle that is applied to the vertical walls of an injection-molded part. In general, you will want your part to have one degree of draft per one inch (2.2 cm) of cavity depth.
Parting line placement. You can easily deal with an undercut by moving the parting line of the mold so it intersects with the part feature. This solution is suitable for many designs with undercuts on an external surface. Don’t forget to adjust the draft angles accordingly.
Cam slides. Integrating cam slides into your part’s design helps it be ejected in a controlled lateral fashion.
Bumpoffs. Bumpoffs function like snaps on a shirt. These tend to work very well when integrated into parts with undercuts, however the material you use must be flexible enough to deform over the mold during ejection.
Hand-loaded inserts. Hand-loaded inserts are just that – machined components placed into a mold by hand before the part is injection molded. These components prevent plastic from flowing into certain areas of a mold, and are then removed by hand after the injection molding process.
Below are a few challenges we often see our customers face when designing parts with undercuts for injection molding. We’ve also provided a simple solution to each.
Complicated parts. The more complicated a part, the more difficult it will be to design an effective undercut. With this in mind, use DFM techniques to design your parts as simply as possible, especially if you think they will need an undercut.
Part rigidity. The more rigid the material you are using, the more difficult it will be to eject it from the mold. While this might not always be possible, think of materials with high degrees of flexibility and elasticity, such as TPE or TPU, when designing parts with undercuts.
Part assembly. Parts with undercuts may pose assembly challenges, especially if components need to precisely fit together. Be sure to design your parts with this in mind, using mating features or assembly aids – and conducting fit testing before committing to a full manufacturing run.
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To find out more, you can also find a breakdown of the costs involved in injection molding, how to design parts for molds, and tips for avoiding common manufacturing defects.
Parts with undercuts tend to complicate mold design, demolding, and part production because they have more intricate geometries than those without.
Ideally, flexible and elastic materials like TPE or TPU are suitable for undercuts.
Yes, more rigid materials pose more challenges during ejection than those with flexible or elastic properties.
The more complex mold, the more expensive it is to create and maintain. Work together with your manufacturing partner to find the best solution for your part.
Intricate undercuts might cause part assembly to be more complicated, so be sure to design with this in mind.
Seeking consistency and predictability in your parts? Check out our guide on repeatability, which highlights the materials that will perform the same way time and time again.
Read articleHow can you create a part or product that’s ready to move from prototype to production? Check out our article, which offers tips and tricks for designing with scalability in mind.
Read articleLearn what to consider when making a choice between 3D printing and injection molding, the benefits of each manufacturing method, and more.
Read articleWant to learn how to design undercuts that don’t cause damage to your parts? Check out our article, which offers tips and tricks for DFM with undercuts, examples of when you might need them, and more. Undercuts in injection-molded parts present a host of challenges to designers and manufacturers. In this article, we’ll take a look at the definition of undercuts, their purpose, applications, and tips for designing parts with them.
Read articleWhen producing parts with injection molding, understanding the range of materials that are available is crucial. Find out more about those materials, their properties, and factors to consider when choosing a material for injection molded parts.
Read articleFind out about the manufacturing technique used to injection mold a second material over or around a part to create a new one.
Read articleWant to learn more about die casting? In this article, we’ll take a look at the process, its history and current uses, advantages, design guidelines, and more.
Read articleIn this article, we’ll take a look at common factors that influence the cost of injection molding, including equipment, labor, and materials – as well as tips for reducing manufacturing costs.
Read articleWhat are the most common defects in the injection molding process and how do you avoid them? This article provides six essential design tips for avoid production defects while reducing the cost and lead time of your molded parts.
Read articleWhat is Geometric Dimensioning and Tolerancing (GD&T) and how is it used? This article explores the basics of how and when to use GD&T to get the best results out of custom part manufacturing.
Read articleDesign for manufacturing (DFM) means taking a design-first approach to manufacturing. In this article, we look at the overall DFM process, the necessary steps for a successful outcome, examples of DFM done right and how to get the most out of your own processes.
Read articleWhat is Delrin and why is it unique among the many manufacturing materials available? Delrin, or POM-H (homopolymer acetal), is used in CNC machining, 3D printing and injection molding to create durable, precise components. This article explores Delrin’s properties and how to get the most out of the material.
Read articleSeeking consistency and predictability in your parts? Check out our guide on repeatability, which highlights the materials that will perform the same way time and time again.
Read articleHow can you create a part or product that’s ready to move from prototype to production? Check out our article, which offers tips and tricks for designing with scalability in mind.
Read articleLearn what to consider when making a choice between 3D printing and injection molding, the benefits of each manufacturing method, and more.
Read articleWant to learn how to design undercuts that don’t cause damage to your parts? Check out our article, which offers tips and tricks for DFM with undercuts, examples of when you might need them, and more. Undercuts in injection-molded parts present a host of challenges to designers and manufacturers. In this article, we’ll take a look at the definition of undercuts, their purpose, applications, and tips for designing parts with them.
Read articleWhen producing parts with injection molding, understanding the range of materials that are available is crucial. Find out more about those materials, their properties, and factors to consider when choosing a material for injection molded parts.
Read articleFind out about the manufacturing technique used to injection mold a second material over or around a part to create a new one.
Read articleWant to learn more about die casting? In this article, we’ll take a look at the process, its history and current uses, advantages, design guidelines, and more.
Read articleIn this article, we’ll take a look at common factors that influence the cost of injection molding, including equipment, labor, and materials – as well as tips for reducing manufacturing costs.
Read articleWhat are the most common defects in the injection molding process and how do you avoid them? This article provides six essential design tips for avoid production defects while reducing the cost and lead time of your molded parts.
Read articleWhat is Geometric Dimensioning and Tolerancing (GD&T) and how is it used? This article explores the basics of how and when to use GD&T to get the best results out of custom part manufacturing.
Read articleDesign for manufacturing (DFM) means taking a design-first approach to manufacturing. In this article, we look at the overall DFM process, the necessary steps for a successful outcome, examples of DFM done right and how to get the most out of your own processes.
Read articleWhat is Delrin and why is it unique among the many manufacturing materials available? Delrin, or POM-H (homopolymer acetal), is used in CNC machining, 3D printing and injection molding to create durable, precise components. This article explores Delrin’s properties and how to get the most out of the material.
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